Abstract: A stretchable flame barrier panel including an interior stretch zone having elastomeric yarns extending across a fibrous base layer of textile fibers and optionally substantially stable lateral selvage zones outboard of the interior stretch zone. In a finished state, the interior stretch zone has substantial stretch and recovery in both the machine direction and the cross-machine direction.

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: Mattress assemblies and pillows are provided that include a flexible biosensor array provided on a layer of the mattress assembly for sensing an electrical conductivity associated with sweat emitted from an end user of the mattress assembly and producing an ionic concentration of at least one electrolyte; and a processor connected to the flexible biosensor array for interpreting the ionic concentration of the at least one electrolyte. Also disclosed are processes for monitoring and analyzing sweat from an end user of the mattress assemblies and pillows.

Abstract: A mattress core includes sandwiched layer of coils that includes coils disposed between a first spacer fabric layer and a second spacer fabric layer. The mattress core also includes a viscoelastic foam disposed beneath the sandwiched layer of coils. A top surface of the first spacer fabric layer is disposed at or adjacent to a top surface of the mattress core. The first spacer fabric layer defines or more first air channels and the second spacer fabric layer defines one or more second air channels. The one or more first air channels extend above the coils included in the sandwiched layer of coils and the one or more second air channels extends below coils.

Abstract: Printed textiles and related manufacturing methods are provided. Textile materials can include laced mesh fabrics made of rigid components. The laced mesh structures are designed for space applications, including but not limited to adaptive and foldable reflectors, capturing systems, debris and micrometeorite shielding, shading systems, sample capturing, and various other applications. The laced mesh structures are used in the generation of tailored, unique radio-frequency antennas and receivers that allow for active tuning/receiving capabilities. The tailored structure can also include multi-material systems mixing dielectric and conductive layers for enhanced, tunable transmission. Laced mesh structures can also be used for enhanced thermal control of components, with the ability to tailor thermal conductivity and emissivity, to create thermal engineered components via the generation of localized or global thermal response (e.g. zone thermal control).

Abstract: A fire retardant cushioning device wherein the cushioning device comprises a main body formed of a fire retardant cover material which is assembled together from panels of fire retardant cover material with the panels being connected together by at least one welded seam extending about the edges of the panels of cover material to form a seamed fire retardant cover material comprising the main body of the cover and the seam(s); and wherein the construction of the cushioning device provides a fire retardant cushioning device having welded seam(s) whereby the welded seam(s) are configured such that they are flame retardant. A fire retardant, infection control cushioning device is also disclosed. The invention also provides a method of manufacturing the fire retardant cushioning device.

Abstract: Protective garments are disclosed having an inner lining with high lubricity and high strength characteristics. The inner lining, in one embodiment, contains spun yarns combined with multifilament yarns. In accordance with the present disclosure, the multifilament yarns are present in the warp direction and in the fill direction. In addition, the multifilament yarns may outnumber the spun yarns in both the warp direction and the fill direction. In this manner, a fabric is produced not only having good lubricity characteristics but also having a balance of properties. For instance, in one embodiment, the shrink properties of the fabric in the warp direction substantially match the shrink properties of the fabric in the fill direction.

Abstract: Ticking having excellent flexibility is described. A woven fabric is obtained by using a multifilament having a monofilament fineness of not more than 0.5 dtex, the number of filaments of 100 or more and a total fineness of not more than 50 dtex and used as ticking. The woven fabric can be made of a polyester.

Abstract: A method of producing a flame resistant ticking includes laminating a flame resistant substrate to a decorative fabric, wherein the substrate is configured to release a chemical vapor that reduces the rate of propagation of a flame along the decorative fabric when the decorative fabric is exposed to flame. The substrate is laminated in direct contact with the inside surface of the decorative fabric. In some embodiments, the laminated ticking is configured to release less than 15 MJ of heat in the first ten minutes when exposed to a flame in accordance with the testing protocol set forth in 16 CFR 1633. Upholstered articles, such as mattresses, mattress foundations, and articles of furniture, may incorporate the flame resistant ticking layer.

Abstract: A composition for a car interior trim including: a polyurethane sponge layer for a car interior trim; and a water-soluble resin layer formed on the polyurethane sponge layer and comprising 20 to 50 parts by weight of a phosphorus-based flame retardant and 1 to 5 parts by weight of a thickener, based on 100 parts by weight of a coating agent blend of one or two more of a water-dispersed polyurethane or an aqueous acrylic resin.

Abstract: A mattress wherein a plurality of independent yarn based fire barrier fabrics encases a plurality of distinct and unattached interior core structures. The plurality of interior core structures include at least a detached and internally flippable upper comfort layer assembly with a plurality of non-homogeneous foams or filling materials encased in a yarn-based fire barrier fabric and a lower, interiorly disposed support core structure with resilient filling materials encased in a yarn-based fire barrier fabric and a fabric cover. The detachable and internally flippable upper comfort layer assembly may be contained in a user accessible compartment that is fashioned into an outer cover assembly.

Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment. The fire-containing compartment includes first and second layers of fire-resistant material selected from the group consisting of a barrier sheet, a high loft batt, and a fire-resistant chemical. The cushioning layer is disposed between the first and second layers of fire-resistant material.

Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.

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: A bedding apparatus may include a frame, a fabric cover, and a liquid containment member. The frame may include first and second members coupled to a base for pivotable motion relative thereto between first and second positions. The base may define an opening surrounded by the first and second members when the first and second members are in the first position. The fabric cover may be coupled to the first and second members and may be maintained in a taught condition by the first and second members when the first and second members are in the first position. The liquid containment member may be disposed below the cover and includes sidewalls and a bottom wall attached to the sidewalls. The sidewalls are attached to the base and extend through the opening. The sidewalls may include a mesh material allowing fluid-flow therethrough. The bottom wall may include a liquid-impermeable material.

Abstract: A removable top panel for a mattress assembly generally includes at least one layer having length and width dimensions sufficient to support a reclining body of the user; a mechanical fastener component disposed at about a perimeter edge of a bottom facing surface of the at least one layer, wherein the mechanical fastener is configured to provide releasable engagement to an underlying mattress body; and a layer of a fire resistant material extending inwardly from the perimeter edge. Also disclosed are mattress assemblies including the removable top panel.

Abstract: A support surface system provides alternating pressure therapy and low air loss therapy simultaneously using a single pump. The system includes a plurality of cells. Each cell has a foam-filled lower chamber and an upper chamber. Fluid communication between the lower and upper chambers is controlled by a normally closed valve that opens if the pressure within the lower chamber exceeds a predetermined threshold pressure. Pressurized air is alternatingly supplied to the lower chambers of a first subset of cells and the lower chambers of a second subset of cells, thereby providing alternating pressure therapy. When the pressure in the lower chamber exceeds the threshold, the valve opens to allow air from the lower chamber to flow into the upper chamber. Air is expelled from the upper chamber through perforations therein, to remove moisture and humidity and possibly reducing the temperature of the micro-climate beneath a patient.

Abstract: Components, such as bedding components including mattresses are disclosed herein. The components include a first layer, a fire-resistant layer affixed to the first layer or an optional additional layer, and a fire-resistant sock. The first layer, the optional additional layer, and fire-resistant layer are disposed within the fire-resistant sock.

Abstract: A mattress wherein a plurality of independent yarn based fire barrier fabrics encases a plurality of distinct and unattached interior core structures. The plurality of interior core structures include at least a detached and internally flippable upper comfort layer assembly with a plurality of non-homogeneous foams or filling materials encased in a yarn-based fire barrier fabric and a lower, interiorly disposed support core structure with resilient filling materials encased in a yarn-based fire barrier fabric and a fabric cover. The detachable and internally flippable upper comfort layer assembly may be contained in a user accessible compartment that is fashioned into an outer cover assembly.

Abstract: A quilted panel for a mattress having gel fibers incorporated therein so as to bring the gel material closer to the top of the mattress such that the benefits of the gel material are better realized by the user. In some embodiments, the gel fibers are incorporated into the FR fiber pad of the quilted panel. In other embodiments, a separate gel fiber pad is positioned within the quilted panel.

Abstract: Components are disclosed that include a first layer and a second layer affixed to the first layer or an optional third layer. At least one of the first layer and the second layer includes a gel foam.

Abstract: Components, such as bedding components including mattresses are disclosed herein. The components include a first layer, a fire-resistant layer affixed to the first layer or an optional additional layer, and a fire-resistant sock. The first layer, the optional additional layer, and fire-resistant layer are disposed within the fire-resistant sock.

Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.

Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment. The fire-containing compartment includes first and second layers of fire-resistant material selected from the group consisting of a barrier sheet, a high loft batt, and a fire-resistant chemical. The cushioning layer is disposed between the first and second layers of fire-resistant material.

Abstract: A composite upholstery panel includes a layer of ticking fabric, a layer of flame and heat-resistant backing fabric, and a layer of resilient flame and heat-resistant cushioning material sandwiched between the layer of ticking fabric and the layer of backing fabric. The composite upholstery panel maintains flame and heat resistant integrity when impinged at any location with a gas flame in accordance with testing protocol set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs (TB-603). However, individually, the ticking layer, backing layer and cushioning layer would fail to maintain flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocol set forth in TB-603.

Abstract: A mattress is constructed of a core comprising a matrix of foam pieces that are bonded together. The core has a thickness in the range from about 1.5 inches to about 10 inches, and more particularly from about 3 inches to about 8 inches, a density of about 4 pounds to 8 pounds per cubic foot, and an IFD of about 28 to 65. The core has a top surface and a bottom surface. A base layer is coupled to the bottom surface of the core, and a cushion layer is coupled to the top surface.

Abstract: A fire-retardant mattress having at least one sleeping side is disclosed that has an inner support compartment with a generally parallelepiped shape with a top side opposite the sleeping side and a fire-containing compartment covering the top side of the inner support compartment and located between the sleeping side and the inner support compartment. The fire-containing compartment includes a first fire-resistant layer consisting essentially of natural fibers, the first fire-resistant layer being in direct contact with the top side of the inner support compartment, a second fire-resistant layer consisting essentially of natural fibers, the second fire-resistant layer located separate from the first self supporting layer of fire-resistant material, and a plurality of combustible cushioning layers positioned between the first and second fire-resistant layers.

Abstract: Mattresses and methods for manufacturing mattresses that have a flame resistant panel, such as a flame resistant border panel. The systems and methods include mattresses that have a flame resistant panel that, in certain embodiments, includes a fire barrier layer made of a batting material and being disposed over a thermoplastic fire barrier layer. The first and second fire barrier layers provide a fire barrier that reduces the transfer of oxygen to the mattress core, thereby reducing the presence of oxygen, which is needed to support combustion of the padding material. Additionally, the invention encompasses methods for manufacturing mattresses.

Abstract: A mattress, foundation, or other upholstered sleep product or article includes a core and barrier material surrounding the core. The barrier material includes flame and heat-resistant material that is configured to prevent combustion of the core when the upholstered article is impinged with a gas flame according to California Technical Bulletin 603 of the State of California Department of Consumer Affairs. The barrier material may include an intumescent material that is configured to swell and char in the presence of a flame so as to form a barrier to the flame and to heat generated by the flame.

Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment and including first and second layers of fire-resistant material. The cushioning layer is disposed between the first and second layers of fire-resistant material.

Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.

Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.

Abstract: An enhanced knit fabric fire barrier for mattresses and method for making same, the fabric barrier including a looped terry knitted fabric with a jersey side and a looped terry side; the jersey side including a fire retardant yarn and a melting yarn; the looped terry side including a fire retardant yarn; the loops in the jersey side are very high loops between about 4 mm and about 8 mm which char to provide a fire barrier for latex and highly volatile foams in mattresses. Also a double knit construction and method for making same, the fabric providing improved performance with the addition of a fire retardant yarn on the outside of the loops. Also, an enhanced fire-resistant full-foam mattress.

Abstract: The present invention relates to flame-retardant Lyocell fibers which include incorporated inorganic additives which are particularly suited for use in flame barriers for articles of manufacture, such as mattresses and upholstered furniture applications.

Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.

Abstract: A fire-retardant mattress having at least one sleeping side is disclosed that has an inner support compartment with a generally parallelepiped shape with a top side opposite the sleeping side and a fire-containing compartment covering the top side of the inner support compartment and located between the sleeping side and the inner support compartment. The fire-containing compartment includes a first fire-resistant layer consisting essentially of natural fibers, the first fire-resistant layer being in direct contact with the top side of the inner support compartment, a second fire-resistant layer consisting essentially of natural fibers, the second fire-resistant layer located separate from the first self supporting layer of fire-resistant material, and a plurality of combustible cushioning layers positioned between the first and second fire-resistant layers.

Abstract: The invention relates to the use of a regenerated cellulose fiber, in which carboxymethylcellulose is incorporated, in a flame-retardant product.

Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment and including first and second layers of fire-resistant material. The cushioning layer is disposed between the first and second layers of fire-resistant material.

Abstract: A mattress is constructed from a mattress body having an upper and a lower deck, which is preferably pervious to moisture and air. A removable panel, which includes a top layer of breathable fabric, a bottom layer of a fabric that forms a moisture barrier, and a batting layer, is placed on at least the upper deck of the mattress body. The removable panel is removably attached along the perimeter of the deck or decks by a fastener, such as a zipper. The panel can be removed from the deck for cleaning and folded and secured by the fastener in an inverted configuration, with the top layer facing outward.

Abstract: A fire-retardant mattress that compartmentalizes bedding material between layers of fire-resistant material. The mattress includes an inner support compartment, a first layer of fire-resistant material adjacent to at least one side of the inner support compartment, at least one layer of cushioning material adjacent to the first layer of fire-resistant material, and a second layer of fire-resistant material adjacent to the at least one cushioning layer, the second layer of fire-resistant material distal to the first layer of fire-resistant material.

Abstract: A mattress construction having a resilient core incorporating deformable foam either alone or in combination with integrated springs with a complimentary flame barrier fabric disposed in overlying relation to the resilient core. The flame barrier fabric has a stitch-bonded construction with elastomeric yarns extending in stitched relation through a fleece substrate of substantially inelastic character incorporating a percentage of flame retardant fibers. In a relaxed condition, the fleece substrate is bunched between stitch lines formed by the elastomeric yarns. Upon the application of tension, the barrier fabric stretches by the extension of the elastomeric stitching yarns in combination with a flattening of the fleece substrate.

Abstract: A removable top panel for a mattress assembly generally includes at least one layer having length and width dimensions sufficient to support a reclining body of the user; a mechanical fastener component disposed at about a perimeter edge of a bottom facing surface of the at least one layer, wherein the mechanical fastener is configured to provide releasable engagement to an underlying mattress body; and a layer of a fire resistant material extending inwardly from the perimeter edge. Also disclosed are mattress assemblies including the removable top panel.

Abstract: The invention provides a corrugated mattress and method for making. The mattress comprises an corrugated foam core, a middle cushioning layer and outer cover layer. The corrugated foam core includes an upper substrate, a lower substrate and a fluted middle substrate the flutes fixed to the upper and lower substrates providing three-dimensional support for the user. The middle cushioning layer may comprise a second corrugated foam product, a cotton batting layer, densified polyester or foam including polyurethane, polyester, polypropylene or polylactic acid and the like. The outer cover layer may comprise cotton or laminated foam comprising, polyurethane, polyethylene, polyester, polypropylene, polylactic acid and the like, the laminate comprising a film independently selected from polyurethane, polyethylene, polyester, polypropylene or polylactic acid and the like. In various embodiments the polymers are food grade polymers such that the mattress is non-toxic.

Abstract: A method of producing a ticking includes laminating a flame retardant backer to film material, wherein the backer releases flame retardant in the vapor phase that reduces the rate of flame propagation along the film material, when the ticking layer is exposed to flame. The backer is laminated in direct contact with the film material. In some embodiments, the laminated ticking is configured to release less than 15 MJ of heat in the first ten minutes when exposed to a flame in accordance with the testing protocol set forth in 16 CFR 1633. Upholstered articles, such as mattresses, mattress foundations, and articles of furniture, may incorporate the ticking layer.

Abstract: The invention relates to a flame-retardant, modified hollow fiber with a silicone-free soft-touch finish feature, and also to a method for production thereof and the use thereof for fiberfill fiber products, in particular in the fiber filling of clothing, cushions, furniture, insulation, quilts, filters, upholstery (e.g., automobiles), sleeping bags, mattress covers and mattresses. In general, the hollow fibers used for these applications are those with flame-retardant, phosphorus-containing compounds. Polyester hollow fibers are used preferably as hollow fibers.

Abstract: A cushion may be constructed of a spacer material having a top layer, a bottom layer and a plurality of loosely arranged spacer elements that extend between the top and bottom layers so as to maintain the top layer and the bottom layer spaced apart from each other. An elastomeric gel material is incorporated into the top layer and/or the bottom layer. The gel material may also extend into at least a portion of the spacer elements.

Abstract: A bed-bug proof mattress comprises an inner section including filler and springs and a continuous outer layer comprised of (i) a bed bug retardant layer made of light weight interlock knit polyester laminated to a hydrophilic breathable polyurethane film, (ii) a fire retardant layer; (iii) a foam layer, the bed bug retardant layer quilted to the fire retardant layer and to the foam layer and containing a seam. The bed bug retardant layer is integrally joined to the fire retardant layer and to the foam layer by being quilted together during the manufacturing of the mattress. The bed bug retardant layer may be approximately one mil thick. The interlock knit provides few places for dust accumulation and the film may act as a barrier for bed bugs. Although the film may be hydrophilic to increases the user's comfort, it may be without pores or even micropores so that it can act as an effective barrier.

Abstract: Mattresses and methods for manufacturing mattresses that have a flame resistant panel, such as a flame resistant border panel. The systems and methods include mattresses that have a flame resistant panel that, in certain embodiments, includes a fire barrier layer made of a batting material and being disposed over a thermoplastic fire barrier layer. The first and second fire barrier layers provide a fire barrier that reduces the transfer of oxygen to the mattress core, thereby reducing the presence of oxygen, which is needed to support combustion of the padding material. Additionally, the invention encompasses methods for manufacturing mattresses.

Abstract: The invention relates to a fire resistant barrier and open flame resistant mattresses, mattress foundations, and upholstered articles having the fire resistant barrier therein for protection. The open flame resistance of the mattresses, mattress foundations, and upholstered articles is determined under a full-scale fire test of a composite article.

Abstract: A flame resistant moisture barrier and a mattress having such a barrier and related methods of manufacture provide mattresses, furniture cushions and other products that provide resistance to flame and moisture.