Abstract: Embodiments disclosed herein include insulation used to insulate elongated members, such a pipe or duct, as examples. The insulation can address a number of features, including but not limited to expansion and compression of insulation material, expansion and compression of the elongated member insulated, and the ability to adapt the insulation for elongated member of different sizes and lengths. In one embodiment, the insulation is comprised of at least one plank comprised of a flexible polymeric foam configured to be wrapped around an elongated member. In order for the insulation to self-adjust to compensate for thermal expansion and contraction of the foam material, the plank is comprised of a plurality of flexible polymeric foam profiles. At least one flexible polymeric foam spacer may also be provided that self-adjusts to compensate for thermal expansion and contraction of the elongated member to prevent or reduce gaps in insulation.

Abstract: Mattress assemblies and related methods employing elastic bands to provide at least a portion of an encasement, including for bedding and seating applications are disclosed. In one embodiment, a mattress assembly is provided. The mattress assembly may include a mattress core and an elastic foam edge-support band compressively engaged along the outer perimeter of the mattress core. The mattress core has a sleep surface and an outer perimeter width and length disposed in a corresponding width and length dimension of the sleep surface. Before assembly, the elastic foam edge-support band has a preassembled inner perimeter width and length, which are less in distance than the width and length of the mattress core. As disposed in the mattress assembly, the elastic foam edge-support band has an assembled inner perimeter width and length which are greater in distance than the preassembled inner perimeter width and length of the elastic foam edge-support band.

Abstract: By forming a plurality of separate, spaced, expansion zones in preselected areas of a foamed plastic product having a desired size and shape, a new foam plastic product is achieved which is capable of being expanded or extended in at least one direction during its use in order to accommodate dimensional changes or requirements. By forming the expansion zones in a precisely desired pattern which extends over a substantial portion of the foam plastic product, the resulting product is capable of being expanded, extended, or adjusted in at least one of its dimensions. In this way, the resulting product is quickly and easily expanded or extended in one direction to fit any desired application surface with ease and simplicity.

Abstract: Related methods to produce unitary or monolithic composite or hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam and a thermoset material are also disclosed. As non-limiting examples, the thermoset material may also be provided as cellular foam. The unitary composite cushioning structure may be formed from the thermoplastic material and the thermoset material. The thermoplastic material provides support characteristics to the unitary composite cushioning structure. The thermoset material provides a resilient structure with cushioning characteristics to the cushioning structure. A stratum, which may be continuously produced, is formed between at least a portion of the cellular thermoplastic foam and at least a portion of the thermoset material as the thermoset material transforms from a non-solid to a solid phase to secure the at least a portion of the thermoset material to the at least a portion of the thermoplastic material to provide a unitary composite cushioning structure.

Abstract: By providing a high speed welding system for fusing adjacent foam profiles in a continuous manufacturing operation, a unique, integrated, foam welding and profile manufacturing system is attained which is capable of producing virtually any desired foam product from foam extrusions without requiring the use of expensive molds or forming components, and which significantly reduces expensive scrap found in prior art construction systems. In accordance with the teaching of the present invention, any desired cross-sectional shape or configuration is capable of being manufactured in fully automated, high-volume, rapid production conditions, with virtual ease and simplicity. Furthermore, by employing the present invention, foam profiles which previously were unattainable due to their structural configurations, are quickly and easily constructed in a mass production operation.

Abstract: By providing a plurality of preformed components which are quickly and easily affixed in engagement with each other, a final construction is realized which peripherally surrounds any desired mattress configuration in cooperating association therewith. In this way, a new foam plastic product is achieved which is capable of being quickly and easily mounted to mattress constructions peripherally surrounding the mattress and providing an enhanced side support system. In this way, any desired mattress size or configuration is capable of being peripherally surrounded with a foam support assembly for enhancing the mattress construction and configuration. Furthermore, by employing the present invention, a rapid, convenient, and virtually labor free assembly is realized.

Abstract: Embodiments disclosed herein include insulation used to insulate elongated members, such a pipe or duct, as examples. The insulation can address a number of features, including but not limited to expansion and compression of insulation material, expansion and compression of the elongated member insulated, and the ability to adapt the insulation for elongated member of different sizes and lengths. In one embodiment, the insulation is comprised of at least one plank comprised of a flexible polymeric foam configured to be wrapped around an elongated member. In order for the insulation to self-adjust to compensate for thermal expansion and contraction of the foam material, the plank is comprised of a plurality of flexible polymeric foam profiles. At least one flexible polymeric foam spacer may also be provided that self-adjusts to compensate for thermal expansion and contraction of the elongated member to prevent or reduce gaps in insulation.

Abstract: By providing a plurality of preformed components which are quickly and easily affixed in engagement with each other, a final construction is realized which peripherally surrounds any desired mattress configuration in cooperating association therewith. In this way, a new foam plastic product is achieved which is capable of being quickly and easily mounted to mattress constructions peripherally surrounding the mattress and providing an enhanced side support system. In this way, any desired mattress size or configuration is capable of being peripherally surrounded with a foam support assembly for enhancing the mattress construction and configuration. Furthermore, by employing the present invention, a rapid, convenient, and virtually labor free assembly is realized.

Abstract: By providing a unique product enhancing step which enables any desired section, portion, or element of a product being produced to be treated in a manner to provide desired enhanced physical, structural, and/or aesthetics characteristics, a new, fully integrated enhanced foam manufacturing system is attained which is capable of producing virtually any desired foam product, with each product incorporating any desired area or zone being formed with a particular physical, structural, and/or aesthetic property, characteristic, or enhancement. In addition, in accordance with the teaching of the present invention, any desired cross-sectional shape or configuration is capable of being manufactured in fully automated, high volume, rapid production conditions, with virtual ease and simplicity, with a specific physical, structural, or aesthetic property incorporated therein.

Abstract: Expandable edge-support members, assemblies, and related methods are disclosed. The expandable edge-support members can be used to provide edge support, including side support and corner support. The expandable edge-support members are suitable for bedding and seating applications as examples. The expandable edge-support members are expandable in length. Thus, the expandable edge-support members can be expanded in length as needed to be utilized to provide edge support for an innerspring having variations in perimeter lengths and different types of innersprings having variations in perimeter lengths. Further, the edge-support members may include a plurality of lateral members, which may be configured to be disposed between adjacent perimeter coils of an innerspring to support attachment to the innerspring.

Abstract: Cushions are disclosed herein. In one embodiment, a cushion is comprised of a plurality of foam profiles each having a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection. The plurality of foam profiles are arranged such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane. In this manner, hollow portions can be formed between adjacent foam profiles. At least one sheet of material is affixed to at least one of the top surface and the bottom surface of the plurality of foam profiles. When a compression force is imposed on the cushion, the hollow portions allow the foam profiles to adapt to deformation. Further, by providing the hollow portions, the cushion can more easily be rolled or wrapped for transport or storage.

Abstract: Encasement assemblies, systems, and related methods employing interlocking support components to provide at least a portion of an encasement, particularly for bedding and seating applications, are disclosed. In this regard in one embodiment, an assembly for bedding or seating is provided. The assembly includes a base having one or more elongated channels disposed therein having a first geometry. The assembly also includes one or more elongated support members each having a rail disposed therein and having a second geometry complimentary to the first geometry. Each rail is interlocked with at least one of the one or more elongated channels such that the one or more elongated support members are attached to the base and extend from the base to provide at least a portion of an encasement. The assembly may also include a flip-up support member(s) disposed in the base to form at least a portion of the encasement.

Abstract: Embodiments disclosed herein include insulation used to insulate elongated members, such a pipe or duct, as examples. The insulation can address a number of features, including but not limited to expansion and compression of insulation material, expansion and compression of the elongated member insulated, and the ability to adapt the insulation for elongated member of different sizes and lengths. In one embodiment, the insulation is comprised of at least one plank comprised of a flexible polymeric foam configured to be wrapped around an elongated member. In order for the insulation to self-adjust to compensate for thermal expansion and contraction of the foam material, the plank is comprised of a plurality of flexible polymeric foam profiles. At least one flexible polymeric foam spacer may also be provided that self-adjusts to compensate for thermal expansion and contraction of the elongated member to prevent or reduce gaps in insulation.

Abstract: Stepped-edge and side-support members, systems, assemblies, and related methods for an innerspring assembly or other core are disclosed. In one embodiment, an innerspring assembly or core is provided having an interior area of a first height surrounded by one or more exterior, perimeter area(s) of shorter height(s) to provide a stepped-edge innerspring assembly or core. At least a portion of side-support members are placed onto at least a portion of the top surface of the perimeter area to provide edge-support for the innerspring assembly or core. In this manner, a greater portion of the side-support members can be disposed in the sleeping area of the innerspring assembly or core since the underlying perimeter area provides spring support to the side-support members. Further, this support can assist in retention and/or recovery of the shape of the side-support members to further prevent or reduce compression set of the side-support members.

Abstract: By providing an elongated profile which incorporates a plurality of indentations formed therein, a load bearing/cushioning/supporting element is realized. By employing this construction, the element accommodates large strain under force, and shows good resiliency and repeated recovery. The element can be produced from a continuous extrusion process with immediate manipulation to re-shape the extrusion profile, or secondary thermal forming process which follows the extrusion process, or blow molding process, or injection molding process.