Abstract: A ventilated mattress includes a ventilation system with an air distribution layer and a gel cushioning layer over the air distribution layer. The air distribution layer may include channels in a surface thereof, while voids that extend through an entire thickness of the gel cushioning layer may include voids that communicate with the channels. As the ventilation system forces air into the air distribution layer, the air may flow through the channels, into and through the voids of the gel cushioning layer, and to a top of the ventilated mattress.

Abstract: A composite mattress includes a pressurizable layer and a top layer. A coiled spring layer may also be included in the composite mattress. The composite mattress may also include a base layer and/or an intermediate layer. A foundation, or rail, may laterally surround the pressurizable layer and the top layer. The composite mattress may include a cover, including a base panel, a periphery, and a top panel. The cover may encase the other components of the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples to customize a mattress by selecting one or more tops from a plurality of available tops for use with one or more bases from a plurality of available bases.

Abstract: A cushioning element includes pressurizable cells. The pressurizable cells of the cushioning elements are grouped into a plurality of sets, with each set of pressurizable cells being independently pressurizable from every other set of pressurizable cells of the cushioning element. The pressurizable cells may extend across a widths of the cushioning element and be arranged in series along the length of the cushioning element. Such a cushioning element may be part of a cushion, such as a mattress, a mattress topper, or the like. Methods for manufacturing the cushioning elements are also disclosed.

Abstract: An article of manufacture, such as a weighted blanket, a cushioning element, or the like, includes an elastomeric element that includes elongated elements that follow nonlinear, partially overlapping paths and voids between adjacent portions of the elongated elements. Such an elastomeric element may define a weighted layer of a weighted blanket, a cushioning layer of a cushioning element of the like. The elastomeric element may be secured directly to a substrate, such as a fabric layer. Alternatively, an adhesion layer may secure the elastomeric element to the substrate. An adhesion layer may cover only a portion of the substrate. A cover may be provided over the elastomeric element. Together, the cover and the substrate may contain the elastomeric element.

Abstract: A mattress assembly includes a base core layer and an inner core located over the base core layer. The inner core includes coil springs. The mattress assembly also includes a side panel assembly located around a perimeter of the inner core. The side panel assembly includes a spacer fabric located over and transverse to the base core layer. The spacer fabric includes a first knit layer, a second knit layer, and an inner fibrous material located therebetween. Methods of forming the mattress assembly are disclosed.

Abstract: A bed linen comprises a single, continuous piece of fabric extending substantially completely across lateral dimensions of the bed linen and including elastomeric fibers and non-elastomeric fibers. The single, continuous piece of fabric is configured to stretch to at least 125 percent of an initial length thereof without damage thereto and to substantially return to the initial length thereof after being stretched. A bedding assembly and a method of forming a bedding assembly are also described.

Abstract: A method for packaging a cushion includes coating a cushioning element with a powder while the cushioning element is in an expanded state and then compressing the cushion to a compressed state. As the cushioning element is compressed, the powder prevents surfaces of the cushioning element (e.g., surfaces of intersecting walls that define hollow buckling columns of a cushioning element formed from an elastomeric polymer extended with a plasticizer, etc.) from adhering to each other. The powder may allow the cushioning element to substantially return to its expanded state substantially immediately following removal of a compressive force from the cushioning element.

Abstract: A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

Abstract: A ventilated mattress includes a ventilation system with an air distribution layer and a gel cushioning layer over the air distribution layer. The air distribution layer may include channels in a surface thereof, while voids that extend through an entire thickness of the gel cushioning layer may include voids that communicate with the channels. As the ventilation system forces air into the air distribution layer, the air may flow through the channels, into and through the voids of the gel cushioning layer, and to a top of the ventilated mattress.

Abstract: A cushion may include a cushioning element. The cushioning element may comprise an elastomeric material and one or more reinforcing features positioned at one or more exterior portions of the cushioning element.

Abstract: A composite mattress includes a base panel of a cover, a base layer, a pressurizable layer, an intermediate layer, a top layer, and a top panel of the cover. A foundation, or rail, laterally surrounds the pressurizable layer, the intermediate layer, and the top layer. A periphery of the cover laterally surrounds the foundation and, with the top panel and the base panel, encases the other components of the composite mattress. A coiled spring layer may also be included in the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples customize a mattress by selecting one or more tops from a plurality of available for use with one or more bases from a plurality of available bases.

Abstract: Extractor systems for extracting a flexible article of manufacture from a mold include an extraction roller, at least one track configured to support the extraction roller, and a trolley configured to carry the extraction roller from a first side of the mold toward a second, opposite side of the mold. Molding systems include a mold and an extractor system. Methods of extracting a flexible article of manufacture from a mold include separating a first platen and a second platen, positioning an extraction roller between the separated first and second platens, engaging the article of manufacture with a row of teeth positioned along the extraction roller, and rotating the extraction roller to wrap the article of manufacture about the extraction roller.

Abstract: A mattress topper for fitting to a mattress may include a lower layer, a side layer configured to extend down along a side of the mattress, and an upper layer overlaying the lower layer and at least partially disposed between the lower layer and the side layer. The mattress topper may also include a seam including threads and extending along peripheral edges of the lower layer and the upper layer and extending through the lower layer, upper layer, and side layer, the lower layer and side layer bearing the threads of the seam. An air table may include a top panel including a plurality of vents extending through the top panel. A method of making a mattress topper with an air table may include lifting the mattress topper with the air table while performing sewing procedures on the mattress topper.