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US 2016/0157630 A1Published application
Bedding product including composite layer and method of manufacture
AssigneeDreamwell, Ltd.
InventorsMichael S. DeFranks, Sheri L. McGuire
Life of this patent
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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.
Claims28
A foam-fiber composite layer comprising:
- an extruded three dimensional polymer fiber layer having constant length, width and height dimensions, the extruded three dimensional polymer fiber layer comprising 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 layer disposed on and in at least one surface of the extruded three dimensional polymer fiber layer, wherein the foam layer extends into a portion of the extruded three dimensional polymer fiber layer.
A mattress comprising:
- at least one foam-fiber composite layer comprising an extruded three dimensional polymer fiber layer having constant length, width and height dimensions, the extruded three dimensional polymer fiber layer comprising 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 layer disposed on and in at least one surface of the extruded three dimensional polymer fiber layer, wherein the foam layer extends into a portion of the extruded three dimensional polymer fiber layer.
A process for manufacturing a foam-fiber composite comprising:
- extruding a polymer through a die comprising multiple apertures onto a conveyor to form a three dimensional polymer fiber layer having constant length, width and height dimensions, and wherein the extruded three dimensional polymer fiber layer comprises randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer;
- injecting or pouring a liquid foam polymer precursor onto and into at least one surface of the extruded three dimensional polymer fiber layer into at least 10 percent of the three dimensional fiber layer;
- and
- curing the liquid foam polymer precursor to form a foam, wherein the foam layer extends into a portion of the extruded three dimensional polymer fiber layer.
1 more element
Dependencies are inferred from the claim text.