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US 12,077,647 B2Granted
Fiber combination
AssigneeBedgear, LLC
InventorEugene Alletto, Jr.
Life of this patent
Estimating the term…
Abstract
A cushioning material includes fibers that define a fiber network and a foam material suspended within the fiber network.
Claims18
A cushioning material comprising:
- a plurality of uncrimped fibers that define a fiber network;
- and
- a foam material suspended within the fiber network,
- wherein the cushioning material comprises about 20% of the fiber network by volume and about 80% of the foam material by volume,
- wherein the cushioning material is compressible from a first height to a second height that is about 25% of the first height, wherein a 25% force is required to compress the cushioning material from the first height to the second height,
- wherein the cushioning material is compressible from a third height to a fourth height that is about 65% of the third height, wherein a 65% force is required to compress the cushioning material from the third height to the fourth height,
- wherein the cushioning material has a support factor defined by a ratio of the 65% force to the 25% force, the ratio being about 4.5, and
- wherein the 65% force is about 14.0 lbs and the 25% force is about 3.0 lbs.
5 more elements
A method of making a cushioning material, the method comprising:
- opening fibers to form a fiber network of uncrimped fibers;
- and
- blending a foam material with the fiber network such that the foam material is suspended within the fiber network,
- wherein the cushioning material comprises 20% of the fiber network by volume and 80% of the foam material by volume,
- wherein the cushioning material is compressible from a first height to a second height that is about 25% of the first height, wherein a 25% force is required to compress the cushioning material from the first height to the second height,
- wherein the cushioning material is compressible from a third height to a fourth height that is about 65% of the third height, wherein a 65% force is required to compress the cushioning material from the third height to the fourth height,
- wherein the cushioning material has a support factor defined by a ratio of the 65% force to the 25% force, the ratio being about 4.5, and
- wherein the 65% force is about 14.0 lbs and the 25% force is about 3.0 lbs.
5 more elements
A cushioning material comprising:
- a plurality of uncrimped fibers that define a fiber network, the fibers comprising polyester, the fibers have a denier between about 0.9D and about 2.8D;
- and
- a foam material permanently suspended within the fiber network, the foam material comprising latex or viscoelastic polyurethane, the foam material comprising chunks having a diameter between 1.0 inch and 1.5 inches, the foam material having a density between 1.8 lbs/ft3 and 4.8 lbs/ft3,
- wherein the cushioning material comprises 20% of the fiber network by volume and 80% of the foam material by volume,
- wherein the cushioning material is compressible from a first height to a second height that is about 25% of the first height, wherein a 25% force is required to compress the cushioning material from the first height to the second height,
- wherein the cushioning material is compressible from a third height to a fourth height that is about 65% of the third height, wherein a 65% force is required to compress the cushioning material from the third height to the fourth height,
- wherein the cushioning material has a support factor defined by a ratio of the 65% force to the 25% force, the ratio being about 4.5, and
- wherein the 65% force is about 14.0 lbs and the 25% force is about 3.0 lbs.
5 more elements
Dependencies are inferred from the claim text.