Abstract:
A mattress comprising asymmetrical coil springs with spring rates that provide comfort to users with different weights. The lower portion of the spring is cylindrical and the upper portion is conical or frustoconical. This arrangement causes the spring to compress with a first substantially constant spring rate for a substantial part of compression, and with a second substantially constant spring rate for a remaining part of compression. The result is a mattress that is sufficiently soft for lighter users and sufficiently firm for heavier users.
Abstract:
The systems and methods described herein include innerspring assemblies or innerspring cores for use with cushioning articles such as mattresses. The innerspring core may have one or more coil springs formed from a high-carbon steel wire alloyed with one or more suitable alloying elements such as titanium and copper and capable of imparting greater strength and durability to the innerspring core.
Abstract:
A flame resistant moisture barrier (10) 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.
Abstract:
The mattress assemblies have an array (100) of springs (104) extending from a sheet. Each spring (104) in the array (100) may be manufactured by choosing a position for the spring, cutting a profile of the sheet spring in the sheet, peeling back or bending the profile or tab of the sheet, and shaping the profile to form the sheet spring. The array (100) of springs may be formed from creating a plurality of such springs (104) along rows and columns. In certain embodiments, multiple sheets may be stacked to form the sheet spring array.
Abstract:
Mattresses and methods for processing a flexible foam material for use in a mattress to' provide a mattress foam material that has more consistent firmness over time and area. The methods include pre-conditioning the foam pad (32) or mattress by applying a force across a substantial portion of a major surface of the mattress to compress or stretch the height of the foam, the length of the foam, and/or the width of the foam to break or open closed cells. In certain embodiments, the force is applied by repeatedly pressing a platen (42) against the foam pad (32) or placing the foam pad (32) between one or more rollers (54, 56).
Abstract:
Mattresses and methods for processing a flexible foam material for use in a mattress to provide a mattress foam material that has more consistent firmness over time and area. The methods include pre-conditioning the foam pad or mattress by applying a force across a substantial portion of a major surface of the mattress to compress or stretch the height of the foam, the length of the foam, and/or the width of the foam to break or open closed cells. In certain embodiments, the force is applied by repeatedly pressing a platen against the foam pad or placing the foam pad between one or more rollers.
Abstract:
Mattresses and methods for manufacturing mattresses that have a flame resistant panel, such as a flame resistant border panel (14). The systems and methods include mattresses that have a flame resistant panel that, in certain embodiments, includes a fire barrier layer (22) made of a batting material and being disposed over a thermoplastic fire barrier layer (20). The first and second fire barrier layers (22,20) 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 progressive spring coil comprises a first spring portion comprising a top end and a bottom end and having a first spring rate, wherein the first spring rate is substantially linear or substantially nonlinear; a second spring portion comprising a top end and a bottom end and having a second spring rate, wherein the second spring rate is substantially linear or substantially nonlinear; and a third spring portion disposed between the first spring portion and the second spring portion, wherein the third spring portion has a third spring rate, wherein the third spring rate is substantially linear or substantially nonlinear.
Abstract:
Panel quilting machines having an in-line splicing tool capable of splicing a new supply of fabric into a web of material being provided to a panel quilting machine while allowing for continuous operation of the panel quilting machine. The systems and methods described herein include, in certain embodiments, an in-line accumulator for creating a temporary in-line supply of material for use by the panel quilting machine while an exhausted supply of material is replaced with a new supply of material.
Abstract:
Corner guards (102,302) suitable for use with a bedding assembly and providing a degree of fire resistance. The corner guards (102,302) may contain fire/flame resistant (FR) polymeric reagents, flammable polymeric reagents combined with one or more FR agent or have an FR coating. Additionally, the corner guards (102,302) may have effective FR properties while substantially maintaining the mechanical properties that allow the corner guard to support and protect the edges of upholstered furniture, such as a foundation or sofa. The corner guards (102,302) arise, at least in part, from the realization that flare ups occurring during the test about the combustion of an FR foundation, result from high burn temperatures causing the corner guard to melt and the subsequently combustion of the melted polymeric material.