Abstract: The methods and structures disclosed herein may be used to make sleep products having foam substrates and gel layers such as mattresses, mattress toppers and pillows. The gel layers may have cooling properties and may include phase change materials. The foam substrates may also be treated with phase change materials.

Abstract: A method of making a sleep product having a cooling gel layer includes providing a mold, coating the mold with a composite material including a mold release and a cooling gel, and introducing a foaming mixture into the mold so that the foaming mixture is in contact with the composite material. The foaming mixture is allowed to rise and cure into a foam layer having an outer surface covered by the composite material. The composite material is both a mold release coating that facilitates removing the foam layer from the mold and a cooling gel coating that remains on the outer surface of the foam layer after the foam layer has been removed from the mold to provide a cooling effect at the outer surface of the foam layer.

Abstract: A bedding product, such as a mattress, mattress topper, or pillow, includes a flexible gel panel having a gel layer with a top surface and a bottom surface, a flexible top layer overlying the top surface of the gel layer, and a flexible bottom layer overlying the bottom surface of the gel layer. The bedding product has a major surface and the flexible gel panel is integrated into the bedding product so that the flexible top layer of the flexible gel panel is juxtaposed with the major surface of the bedding product. The flexible gel panel removes body heat during use.

Abstract: A method of making a sleep product having a cooling gel layer includes providing a mold, coating the mold with a composite material including a mold release and a cooling gel, and introducing a foaming mixture into the mold so that the foaming mixture is in contact with the composite material. The foaming mixture is allowed to rise and cure into a foam layer having an outer surface covered by the composite material. The composite material is both a mold release coating that facilitates removing the foam layer from the mold and a cooling gel coating that remains on the outer surface of the foam layer after the foam layer has been removed from the mold to provide a cooling effect at the outer surface of the foam layer.

Abstract: A method of manufacturing and packaging a mattress includes compressing a finished mattress to flatten the finished matter and rolling said finished mattress into a cylinder. The method includes placing the compressed and rolled mattress into a bag, and sealing the bag to form a sealed bag containing the compressed and rolled finished mattress. The method includes providing an elongated container having a closed bottom end and an open upper end, and passing the sealed bag containing the compressed and rolled finished mattress through the open upper end and into the elongated container. A cap is placed over the open upper end of the elongated container.

Abstract: A bedding product, such as a mattress, mattress topper, or pillow, includes a flexible gel panel having a gel layer with a top surface and a bottom surface, a flexible top layer overlying the top surface of the gel layer, and a flexible bottom layer overlying the bottom surface of the gel layer. The bedding product has a major surface and the flexible gel panel is integrated into the bedding product so that the flexible top layer of the flexible gel panel is juxtaposed with the major surface of the bedding product. The flexible gel panel removes body heat during use.

Abstract: A bedding product, such as a mattress, mattress topper, or pillow case, includes a flexible gel panel having a cured gel layer with a top surface and a bottom surface, a flexible top layer overlying the top surface of the cured gel layer, and a fabric bottom layer overlying the bottom surface of the cured gel layer. The bedding product has a major surface and the flexible gel panel is integrated into the bedding product so that the flexible top layer of the flexible gel panel is juxtaposed with the major surface of the bedding product. The flexible gel panel is removable from the bedding product for laundering the bedding product.

Abstract: A bedding product, such as a mattress, mattress topper, or pillow case, includes a flexible gel panel having a cured gel layer with a top surface and a bottom surface, a flexible top layer overlying the top surface of the cured gel layer, and a fabric bottom layer overlying the bottom surface of the cured gel layer. The bedding product has a major surface and the flexible gel panel is integrated into the bedding product so that the flexible top layer of the flexible gel panel is juxtaposed with the major surface of the bedding product. The flexible gel panel is removable from the bedding product for laundering the bedding product.