Abstract: Mattress toppers for mattress assemblies and pillowtop mattress assemblies generally includes a convoluted foam layer including a convoluted upper surface and a bottom planar surface. The convoluted foam layer includes a convoluted upper surface and a bottom planar surface. The convoluted upper surface comprising repeating geometric depressions defined by an outer geometric-shaped outer wall and a concentric shaped inner wall. The geometric depression can be defined by a geometric outer wall, e.g., hexagonally shaped, and a concentric inner wall, e.g., circular shaped.

Abstract: Antiviral-treated fabric layers for mattress assemblies includes a silver halide and liposome carrier. Additionally, the envelope encapsulating a cushioning material can include an antiviral-treated fabric. The antiviral-treated fabric can include silver halide and a liposome carrier, wherein the liposome carrier is a vesicle.

Abstract: Bedding components generally include a desiccant applied or infused into a selected bedding component. The desiccant can be microencapsulated, applied as a topical solution, and/or provided within a container including a moisture permeable membrane.

Abstract: Compressible mattress assembly packages and processes for packaging a compressible mattress assembly for a bed in a box application generally include the addition of a humidifying agent within the package. The humidifying agent provides moisture within the package, which allows the compressed mattress to effectively recover to its uncompressed state when unpackaged with minimal or no defects.

Abstract: Mattress toppers for mattress assemblies and pillowtop mattress assemblies generally includes a convoluted foam layer including a convoluted upper surface and a bottom planar surface. The convoluted foam layer includes a convoluted upper surface and a bottom planar surface. The convoluted upper surface comprising repeating geometric depressions defined by an outer geometric-shaped outer wall and a concentric shaped inner wall. The geometric depression can be defined by a geometric outer wall, e.g., hexagonally shaped, and a concentric inner wall, e.g., circular shaped.

Abstract: Multilayered mattress assemblies include at least one elongated elastic wrap compressively looped about at least two layers of the mattress assembly to maintain the at least two layers in a fixed relationship relative to one another.

Abstract: Mattresses, cushions, and body-support mats or pads include a plurality of layers extending in a depth direction from a resting surface, where the resting surface is capable of supporting user(s), to a lower surface, the lower surface being opposite the resting surface. The plurality of layers include a comfort layer that forms an upper layer proximate to the resting surface, where the comfort layer includes deformable walls separated by voids and the deformable walls include a plurality of fiber strands embedded in a cushioning media.

Abstract: Mattress assemblies including fiber panels generally include bicomponent fibers including optically active particles within a core thereof. The bicomponent fibers can be treated with a fire retardant or untreated and blended with fire retardant fibers. The bicomponent fibers are configured to transform radiant body heat of an end user.

Abstract: Antiviral-treated fabric layers for mattress assemblies includes a silver halide and liposome carrier. Additionally, the envelope encapsulating a cushioning material can include an antiviral-treated fabric. The antiviral-treated fabric can include silver halide and a liposome carrier, wherein the liposome carrier is a vesicle.

Abstract: A composite layer for use in a bedding product such as a mattress and a method of manufacture are disclosed. The composite layer generally includes an extruded three dimensional fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer. Also disclosed are processes for manufacturing a foam-fiber composite.

Abstract: Temperature management bedding systems for mattresses and quilt panels generally include a trilayer of active components including a phase change material applied to a top surface of a flexible substrate thereof, a fire retardant layer underlying the flexible substrate including hydrophilic rayon fibers treated with ammonium polyphosphate; and a vertically oriented fiber batting layer underlying the first retardant layer including an elastomeric binder. The temperature management bedding systems provide heat control and mass transfer of moisture from the bedding surface.

Abstract: Temperature management bedding systems for mattresses and quilt panels generally include a trilayer of active components including a phase change material applied to a top surface of a flexible substrate thereof, a fire retardant layer underlying the flexible substrate including hydrophilic rayon fibers treated with ammonium polyphosphate; and a vertically oriented fiber batting layer underlying the first retardant layer including an elastomeric binder. The temperature management bedding systems provide heat control and mass transfer of moisture from the bedding surface.

Abstract: Mattress assemblies including fiber panels generally include bicomponent fibers including optically active particles within a core thereof. The bicomponent fibers can be treated with a fire retardant or untreated and blended with fire retardant fibers. The bicomponent fibers are configured to transform radiant body heat of an end user.

Abstract: Mattress assemblies including antimicrobial panels formed of porous foam or fibers generally include an antimicrobial including a polymer in an amount from 90 to 99.9 weight percent, an oxidant in an amount from 0.004 to 1 weight percent, and a silver metal from 0.002 to 1 weight percent, wherein the weight percent is based on a total weight of the antimicrobial.

Abstract: A composite layer for use in a bedding product such as a mattress and a method of manufacture are disclosed. The composite layer generally includes an extruded three dimensional fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer. Also disclosed are processes for manufacturing a foam-fiber composite.

Abstract: Flame retardant panels and methods of manufacture generally include a batting material including a layer having a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface; and a binder material.

Abstract: The present invention relates to a process for making high loft, nonwoven material by providing either natural and/or synthetic fibers, providing a low melt binder fiber, mixing the low melt binder fiber and the natural and/or synthetic fibers to form a web, cross-lapping the web, drafting the web with a drafter, heating the drafted web to a temperature sufficient to melt the low melt binder fibers, and cooling the web thereby forming a structural nonwoven material. The nonwoven batt can be cross-lapped between 2 and 10 layers and when the batt is cooled and has structural rigidity, the tensile strength in the machine direction is at least 50% of the tensile strength in the cross-direction. The batt weight is in a range of 0.25 oz/ft2 to 2.0 oz/ft2. The low melt binder fibers comprise 10 to 30 wt. % of the nonwoven batt and the synthetic and/or natural fibers comprise about 70 to 90 wt. %.

Abstract: The present invention relates to process for making a light-weight, high loft nonwoven fabric. The process adds a drafter to a conventional nonwoven process in order to increase the production rate. Additionally, the invented process improves the quality of the manufactured fabric by increasing the tensile strength in the machine direction, providing balanced strength in the machine and cross directions, and enhancing resiliency. The process blends polyester fiber with a low melt fiber or low melt bicomponent fiber to form a web. The web is optionally carded and cross lapped before being drafted. Thereafter, the web is heated in an oven having sufficient heat to melt the low melt fiber then cooled to set the properties.

Abstract: The present invention concerns a flame retardant (FR) nonwoven fabric useful in wall panels, especially for cubicles. The nonwoven fabric comprises from about 15 to 65 weight % of a low melt binder, and least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin coated synthetic or natural fibers, and optional nonbonding fibers. The total amount of FR fibers and FR resin coated synthetic or natural fibers is about 30-85 wt. % of the fabric. The present invention also contemplates a wall panel constructed from the nonwoven fabric comprising FR rayon fibers, FR acrylic fibers, FR melamine fiber or a combination of these, and/or FR resin coated synthetic or natural fibers, with about 15 to about 65 weight % low melt binder. The wall panel from this construction passes the ASTM E 1354, 1999 tests. Preferably the nonwoven fabric has a batt weight of at least about 40 oz./sq. yd. and preferably between about 40 oz./sq. yd. and 60 oz./sq. yd.

Abstract: The present invention concerns a flame retardant (FR) nonwoven fabric useful in household goods and particularly for mattresses. The nonwoven fabric comprises at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber and optionally synthetic and/or natural fiber mechanically bound together by a needlepunch process. From this nonwoven fabric, many household goods such as drapes, curtains, rugs, bedding and particularly mattresses may be constructed. The present invention also contemplates a mattress constructed from the nonwoven fabric comprising FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber. The mattress from this construction passes the California Test Bulletin 603 stringent conditions for mattresses used in residential places. Preferably the nonwoven fabric has a batt weight of at least 2.25 oz./sq. yd. and preferably between 2.25 oz./sq. yd. and 20 oz./sq.