Back to results
US 11,105,040 B2Granted
Bedding product including composite layer and method of manufacture
AssigneeDreamwell, Ltd.
InventorsMichael S. DeFranks, Sheri L. McGuire
Life of this patent
Estimating the term…
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.
Claims20
A single foam-fiber composite layer consisting of:
- an extruded three dimensional polymer fiber portion having constant length, width and height dimensions, wherein the extruded three dimensional polymer fiber portion has a bottom surface, a top surface, and peripheral edges extending between the top and bottom surfaces, the extruded three dimensional polymer fiber portion consisting of randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer;
- and
- a foam portion disposed on and in a portion of the bottom surface and the peripheral edges of the extruded three dimensional polymer fiber portion, wherein the foam portion extends into at least 10 percent of the extruded three dimensional polymer fiber portion to provide the single roam-fiber composite layer with a foam-only portion, a roam and fiber portion, and a fiber-only portion, wherein a bottom surface and peripheral edges of the single foam-fiber composite layer consists of the foam-only portion.
A mattress comprising:
- at least one single foam-fiber composite layer consisting of an extruded three dimensional polymer fiber portion having constant length, width and height dimensions, wherein the extruded three dimensional polymer fiber portion has a bottom surface, a top surface, and peripheral edges extending between the top and bottom surfaces, the extruded three dimensional polymer fiber portion consisting of randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer;
- and
- a foam portion disposed on and in a portion of the bottom surface and the peripheral edges of the extruded three dimensional polymer fiber portion, wherein the foam portion extends into at least 10 percent of the extruded three dimensional polymer fiber portion to provide the foam-fiber composite layer with a foam-only portion, a foam and fiber portion, and a fiber-only portion, wherein a bottom surface and peripheral edges of the at least one single foam-fiber composite layer consists of the foam-only portion.
Dependencies are inferred from the claim text.