Abstract: An apparatus and method for inverting a flexible foam sheet being conveyed on a moving conveyer grips the leading edge of the foam sheet with a clamp and raises the clamp above the moving conveyor surface. As the leading edge is held by the clamp, the foam sheet progressively separates from the moving conveyor surface and is curled back over itself until the trailing edge of the foam sheet passes beyond the clamp and the foam sheet is inverted. Upon releasing the clamp, the inverted foam sheet is deposited onto the moving conveyor, now with the former leading edge comprising the trailing edge. In an embodiment, the foam sheet comprises two profiled layers nested together, and the clamp lifts the leading edge of the top profiled layer to separate and invert such top layer from the bottom layer, depositing the inverted top layer onto the conveyor behind the bottom layer.

Abstract: A method of making flexible polyurethane foams mixes a polyol (a hydroxyl group containing compound) with a cesium and/or rubidium fluoride catalyst, and reacts such mixture with at least one isocyanate. The cesium and/or rubidium fluoride may be used as the sole catalyst, replacing the blowing and gelling catalysts, such as amines, and metallic catalysts, such as a tin catalyst. Or, the cesium and/or rubidium fluoride may be used as a catalyst promoter in combination with traditional amine blowing and gelling catalysts and tin catalysts. The resulting flexible polyurethane foams exhibit increased thermal conductivity and lower levels of volatile organic compound emissions.

Abstract: Body support systems such as mattresses include breathing layers that define internal air flow guides and form part of the structure for pressure redistribution. At least one air flow unit is coupled for fluid communication with the breathing layers so that heat and moisture may be drawn away from an uppermost comfort layer or body-supporting layer, through the breathing layers, and exhausted out of the body support system. Alternatively, air may be directed through permeable portions of the layers of the body support system to the uppermost layer, particularly at the torso supporting region.

Abstract: A method of making flexible polyurethane foams mixes a polyol (a hydroxyl group containing compound) with a cesium and/or rubidium fluoride catalyst, and reacts such mixture with at least one isocyanate. The cesium and/or rubidium fluoride may be used as the sole catalyst, replacing the blowing and gelling catalysts, such as amines, and metallic catalysts, such as a tin catalyst. Or, the cesium and/or rubidium fluoride may be used as a catalyst promoter in combination with traditional amine blowing and gelling catalysts and tin catalysts. The resulting flexible polyurethane foams exhibit increased thermal conductivity and lower levels of volatile organic compound emissions.

Abstract: A compressible or retractable support (10, 80, 90, 100) is installed inside an air blower cavity (36) of a body support system (30), such as a medical mattress with forced air flow. The support is compressed or retracted within the cavity when the air blower (40) is inserted in the dynamic configuration of the body support system. The support rebounds to an uncompressed state to fill a greater portion of the air blower cavity when the air blower is removed to convert the body support system to a static configuration.

Abstract: A method of making a headrest includes folding a first sheet of foam into a foam sleeve. The foam sleeve is slid over an internal core part of the headrest. The foam sleeve and the core part in turn are covered with an outermost cover. The cover is formed from (i) a first layer of material corresponding to a front face of the cover, (ii) a second sheet of foam having a periphery substantially the same shape as the first layer of material, affixed to a backside of the first layer, (iii) a second layer of the material corresponding to a rear face of the cover, and (iv) a third sheet of foam having a periphery substantially the same shape as the second layer of material, affixed to a backside of the second layer. The front and rear faces are joined together to form the cover.

Abstract: Body support systems include central cores having one or more internal air flow guides that form part of each system for pressure redistribution, and withdrawal of heat and moisture away from an uppermost comfort layer or body-supporting layer(s). During operation of the system, heat and/or moisture is directed from the uppermost comfort layer or body-supporting layer(s) into the central core portion of the body support system and out of the body support system. The internal air flow guide(s) are formed of cellular polymer material and are coupled to the uppermost comfort layer to form an air flow path.

Abstract: A compressible or retractable support (10, 80, 90, 100) is installed inside an air blower cavity (36) of a body support system (30), such as a medical mattress with forced air flow. The support is compressed or retracted within the cavity when the air blower (40) is inserted in the dynamic configuration of the body support system. The support rebounds to an uncompressed state to fill a greater portion of the air blower cavity when the air blower is removed to convert the body support system to a static configuration.

Abstract: A compressible or retractable support is installed inside an air blower cavity of a body support system, such as a medical mattress with forced air flow. The support is compressed or retracted within the cavity when the air blower is inserted in the dynamic configuration of the body support system. The support rebounds to an uncompressed state to fill a greater portion of the air blower cavity when the air blower is removed to convert the body support system to a static configuration.

Abstract: Body support systems such as mattresses include breathing layers that define internal air flow guides and form part of the structure for pressure redistribution. At least one air flow unit is coupled for fluid communication with the breathing layers so that heat and moisture may be drawn away from an uppermost comfort layer or body-supporting layer, through the breathing layers, and exhausted out of the body support system. Alternatively, air may be directed through permeable portions of the layers of the body support system to the uppermost layer, particularly at the torso supporting region.

Abstract: Body support systems such as mattresses include breathing layers that define internal air flow guides and form part of the structure for pressure redistribution. At least one air flow unit is coupled for fluid communication with the breathing layers so that heat and moisture may be drawn away from an uppermost comfort layer or body-supporting layer, through the breathing layers, and exhausted out of the body support system. Alternatively, air may be directed through permeable portions of the layers of the body support system to the uppermost layer, particularly at the torso supporting region.

Abstract: Body support systems include central cores having one or more internal air flow guides that form part of each system for pressure redistribution, and withdrawal of heat and moisture away from an uppermost comfort layer or body-supporting layer(s). During operation of the system, heat and/or moisture is directed from the uppermost comfort layer or body-supporting layer(s) into the central core portion of the body support system and out of the body support system. The internal air flow guide(s) are formed of cellular polymer material and are coupled to the uppermost comfort layer to form an air flow path.

Abstract: A layered mattress including a first layer having a first support surface facing substantially externally and a second support surface opposite the first support surface; a specialized layer having a top support surface adjacent the second support surface of the first layer, a bottom support surface, and a plurality of holes defined to extend through the specialized layer; a second layer having a third support surface adjacent the bottom support surface of the specialized layer and a fourth support surface opposite the third support surface; and a pad having a fifth support surface adjacent the fourth support surface of the second layer and a sixth support surface opposite the fifth support surface.

Abstract: A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft3/ft2/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress and contain one or more gels.

Abstract: A crawling insect abatement matrix, system and method includes a cellular, nonwoven, wet laid or fibrous substrate with a shaped surface to which diatomaceous earth (diatomite, kieselgur, amorphous silica) particles are bound, either in situ or with a binder/coating applied to the substrate. A representative cellular substrate is polyurethane foam with a convoluted or otherwise shaped surface to which a coating that includes diatomaceous earth particles has been applied. The substrate is formed as a sheet, mat or pad that may be installed between a mattress and bedding structure or bedding textiles or below furniture articles, or in clothing compartments, or formed as a tape that may be applied to a surface of a mattress, a bedding structure, a headboard, bedding textiles, or to a clothing compartment.

Abstract: A polyurethane foam sponge that picks up at least 80% of water in a wipe dry performance test is made by variably felting (compressing under heat and pressure) a foam sheet to a compression ratio of about 1.05 to 2.9. The resulting foam sponge has from 5% to 25% of its top and bottom surface portions modified by the variable felting, while its core portion remains substantially unmodified.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.