Abstract: A flooring underlayment comprising a plurality of recycled fibers formed into a nonwoven fiber batt, and a resin intermixed with the recycled fibers in the nonwoven fiber batt, the resin bonding the recycled fibers together. The invention includes a flooring underlayment comprising a plurality of recycled fibers formed into a nonwoven fiber batt, wherein the nonwoven fiber batt is formed using a method selected from the group comprising resin bonding, thermal bonding, mechanical bonding, and combinations thereof. The invention includes a nonwoven fiber batt comprising a blend of recycled fibers and binder fibers formed into a nonwoven fiber batt, and a resin intermixed with the recycled fibers and the binder fibers in the nonwoven fiber batt, wherein the resin and the binder fibers bond the recycled fibers and the binder fibers in the nonwoven fiber bait together.

Abstract: A high loft fiber batt is formed from a blend comprising charred thermoplastic fibers and about 10-15 percent by volume polyester binder fibers, wherein the fiber batt is suitable for use as a fire barrier layer. Another embodiment of a high loft fiber batt is formed from a blend of at least 15 percent by volume charred thermoplastic fibers, at least 15 percent by volume polyester carrier fibers, and about 10-15 percent by volume polyester binder fibers. Still another embodiment of a high loft fiber batt comprises a blend of about equal amounts by volume of charred thermoplastic fibers and polyester carrier fibers, wherein the fiber batt is suitable for use as a fire barrier layer. These high loft fiber batts may be used as a fire barrier layer in various different products, including seating and insulation for vehicles and aircraft, bedding, upholstery and furniture.

Abstract: A mattress or mattress foundation comprising a core and a ticking surrounding the core, the core comprising a spring assembly, a flammable core component positioned above the spring assembly, and a fire resistant (FR) insulator pad positioned between a spring assembly and the flammable core component, wherein the FR Insulator pads protects the flammable core component by delaying the penetration of the flammable core component by the spring assembly during a partial or complete consumption of the mattress or mattress foundation by a fire. The FR insulation pad may be a nonwoven fiber batt comprising a homogeneous blend of shoddy fibers and oxidized polyacrylonitrile fibers. If the mattress or mattress foundation further comprises a surface FR layer, the surface FR layer is the primary FR layer for the mattress or mattress foundation and the FR Insulator pad is the secondary FR layer for the mattress or mattress foundation.

Abstract: resent invention relates to a process of forming a multi-layer pad of a non-woven fiber batt and a foam layer having conforming convoluted surfaces and to a multi-layer pad incorporating a non-woven fiber batt and foam layer. The process of forming a non-woven batt layer and a foam layer having conforming convoluted surfaces comprises transporting each layer along its longitudinal dimension while compressing each layer along its lateral dimension. Concomitantly with compression, each layer is cut transversely along its lateral dimension to separate each layer into an upper segment and a lower segment and to provide conforming convoluted surfaces on the segments of each layer, the convoluted surfaces comprised of upstanding projections and depressions.

Abstract: Present invention relates to a process of forming a multi-layer pad of a non-woven fiber batt and a foam layer having conforming convoluted surfaces and to a multi-layer pad incorporating a non-woven fiber batt and foam layer. The process of forming a non-woven batt layer and a foam layer having conforming convoluted surfaces comprises transporting each layer along its longitudinal dimension while compressing each layer along its lateral dimension. Concomitantly with compression, each layer is cut transversely along its lateral dimension to separate each layer into an upper segment and a lower segment and to provide conforming convoluted surfaces on the segments of each layer, the convoluted surfaces comprised of upstanding projections and depressions.

Abstract: An apparatus for testing properties of a product comprising a thermal barrier layer comprises an ignition source, a test stand that extends a sample of the product over the ignition source, and a means for measuring thermal transfer across the sample. The apparatus may further comprise a means for measuring thermal transfer across each layer of the sample. A method for testing properties of a product comprising a thermal barrier layer comprises supporting a sample of the product over an ignition source, heating the sample via the ignition source, and determining a thermal differential across the sample. The method may further comprise determining a thermal differential across each layer of the sample.

Abstract: A seat cushion or other resilient structure includes a foam inner core combined with layers of varying density fiber batts to impart desirable comfort characteristics, support features and durability thereto. In one embodiment, the foam core is positioned between intermediate layers of low loft fiber batts of relatively high densities. In turn, the intermediate batts are sandwiched between outer high loft fiber batts having relatively low densities. Alternately, the foam core comprises one or more intermediate layers of relatively high density fiber batts that are positioned within the foam core to create one or more fiber batt subcores. The outer high loft fiber batts sandwich the foam core comprising the fiber batt subcores to create the resilient structure.

Abstract: A bi-layered fire resistant (FR) nonwoven fiber batt and an associated method for manufacturing the same. The bi-layered FR nonwoven fiber batt includes a first, gray, FR layer, formed from a blend of black oxidized polyacrylonitrile (oxidized PAN), white dry polyester carrier fibers and white low-melt polyester binder fibers, and a second, white, layer, formed from a blend of white FR rayon, white dry polyester carrier fibers and white low-melt polyester binder fibers, disposed in a conforming relationship with the first, gray, FR layer.

Abstract: Disclosed are uni-layer and bi-layer FR nonwoven fiber batts formed of various blends of charring fibers such as FR treated rayon, oxygen-depleting fibers such as modacrylic fibers and nonwoven fibers such as carrier fibers and binder fibers and associated methods for forming the same. Variously, the uni-layer and bi-layer FR nonwoven fiber batts may include layers formed entirely of blends of charring fibers and nonwoven fibers, layers formed entirely of blends of oxygen-depleting fibers and nonwoven fibers and/or layers formed of blends of charring fibers, oxygen-depleting fibers and nonwoven fibers.

Abstract: A seat cushion or other resilient structure includes a foam inner core combined with layers of varying density fiber batts to impart desirable comfort characteristics, support features and durability thereto. In one embodiment, the foam core is positioned between intermediate layers of low loft fiber batts of relatively high densities. In turn, the intermediate batts are sandwiched between outer high loft fiber batts having relatively low densities. Alternately, the foam core comprises one or more intermediate layers of relatively high density fiber batts that are positioned within the foam core to create one or more fiber batt subcores. The outer high loft fiber batts sandwich the foam core comprising the fiber batt subcores to create the resilient structure.

Abstract: A method of manufacturing a pocketed coil spring assembly comprising vertically spacing two sheets of fabric apart so that the sheets are generally parallel to one another. The sheets are then attached together along one end edge and rows of coil springs are inserted between the sheets. After each row of coil springs is inserted between the sheets, the sheets are attached together along transversely extending lines of attachment in alternative planes of the pocketed coil spring assembly. These steps of inserting rows of coil springs and attaching the sheets together in alternative planes occurs sequentially until an appropriate length of the assembly is obtained.

Abstract: Apparatus including a mattress support for supporting a mattress lying on a first major face or panel thereof and conveying the mattress as a sewing operation, such as an edge sewing and taping operation, is performed with respect to the first major face. A mattress flipping mechanism is provided and may include a pivoting support portion of the mattress support connected to a powered lift mechanism. Mattress elevating units are provided to create slack in the top panel of the mattress for easier grasping by the operator during a sewing operation. A mattress guide arm is provided for holding the mattress down during the sewing operation. A mattress inclining mechanism is provided for selectively moving the mattress from a generally horizontal orientation used for mattress conveying and flipping operations to an inclined orientation used during sewing to gravity feed the mattress into engagement with the sewing machine.

Abstract: A pocketed coil spring assembly comprising a plurality of transversely extending integrally connected fabric blocks. Each block is defined between two sheets of fabric by transversely extending lines of attachment of the sheets to each other. Successive lines of attachment are located alternatively in the upper and lower planar surfaces of the assembly. The blocks may be further connected with fasteners in one of the planar surfaces of the assembly. The blocks may contain either continuous bands of coil springs or individual coil springs, but in any event, the springs within adjacent blocks are oppositely oriented to create a balanced spring assembly in which there is no tendency for the springs to tilt upon compression of the assembly.

Abstract: A spring interior of a mattress comprising a plurality of longitudinally extending bands of springs disposed side by side and connected together with helical lacing wires in the top and bottom faces of the bands. Each band of springs comprises a single length of wire formed into a plurality of coil springs interconnected by innerconnecting segments located alternatively in the top and bottom faces of the bands. The spring interior is characterized by longitudinally extending sections of differing firmnesses throughout the length of the spring interior. The different firmnesses in the different sections of the spring interior are attributable to different configurations of the innerconnecting segments. The innerconnecting segments within the firmer sections of the mattress have a deeper V-shaped indentation than the portions of the bands of springs in the less firm sections of the mattress.

Abstract: An inner spring core comprising a plurality of coil springs arranged in rows and columns having an improved border firmness adjuster around the periphery of the core. The improved border firmness adjuster comprises one of more inflatable pneumatic members positioned inwardly of the outer edges of the outermost coil springs in a space between two adjacent convolutions of each of the outermost coil springs. The pneumatic member or members is capable of variably adjusting the firmness of at least one edge of the mattress.

Abstract: This invention is directed to an improved mattress and mattress core which provide increased firmness along the edges and transverse center section. The mattress includes a mattress core, padding over at least one side of the core, and an upholstered covering encasing the mattress core and padding. The improved mattress core has a rectangular coil spring assembly and a pair of rectangular outer border rods surrounding the assembly in the top and bottom planes of the mattress core. The improved core also includes means for increasing the firmness of the edges and the transverse center portion of the mattress, including a pair of rectangular inner border rods spaced inwardly from an outer border rod in at least one of the top and bottom planes of the rectangular coil spring assembly. A preferred embodiment has one pair of inner border rods in the top plane and a second pair in the bottom plane substantially underlying the first pair.

Abstract: Apparatus including a mattress support for supporting a mattress lying on a first major face or panel thereof and conveying the mattress as a sewing operation, such as an edge sewing and taping operation, is performed with respect to the first major face. A mattress flipping mechanism is provided and may include a pivoting support portion of the mattress support connected to a powered lift mechanism. In one preferred embodiment the mattress support includes a split conveyor and the pivoting support portion of the mattress support is disposed within the space defined between adjacent belts of the split conveyor. Mattress elevating units are provided to create slack in the top panel of the mattress for easier grasping by the operator during a sewing operation. A mattress guide arm is provided for holding the mattress down during the sewing operation.

Abstract: A box spring assembly for use as a foundation for a bedding mattress has a triple beam frame. The frame has three layers of which the bottom layer consists of longitudinal side rails equally spaced from a center rail and connected at each end to a double thickness end rail consisting of a lower and upper board. The middle layer of the frame includes a number of transverse slats equally spaced between the upper board end rails positioned at each lengthwise end of the box spring assembly. The lower board end rails underlie the upper board end rails and are in the bottom plane of the frame. The top layer of the frame consists of longitudinal slats spaced atop the transverse slats and upper board end rails. The triple beam frame is constructed of metal, wood, or a combination thereof. Coil springs are secured to the longitudinal slats in the box spring assembly.

Abstract: A border support spring has a pair of complementary torsion wires for providing increased resilient border support to a mattress spring assembly. Each torsion wire of the present invention is bent to have an elongated center section having a pair of spaced ends from which extend divergently projecting transverse arms. Each transverse arm terminates in an end portion which is adapted to be secured to the top or bottom border wire of the mattress spring assembly. The end portions and center sections are each generally orthogonal to the orientation of the transverse arms. The center sections of the pair of torsion wires journal together to prevent relative translational movement, but permit pivotal relative movement between the transverse arms. A helical laced wire is used to journal the center sections of the torsion wires together and extends substantially the entire length of the center sections.