FOR BEDDING PRODUCTS

BACKGROUND

[0001] The present disclosure generally relates to bedding products and methods of manufacture, and more particularly, to bedding products including a pre-conditioned three- dimensional polymeric fiber matrix layer.

[0002] One of the ongoing problems associated with all-foam mattress assemblies as well as hybrid foam mattresses (e.g., foam mattresses that include, in addition to one or more foam layers, spring coils, bladders including a fluid, and various combinations thereof) is user comfort. To address user comfort, mattresses are often fabricated with multiple layers having varying properties such as density and hardness, among others, to suit the needs of the intended user. One particular area of concern to user comfort is the level of heat buildup experienced by the user after a period of time. Additionally, some mattresses can retain a high level of moisture, further causing discomfort to the user and potentially leading to poor hygiene.

[0003] Unfortunately, the high density of foams used in current mattress assemblies, particularly those employing traditional memory foam layers that typically have fine cell structure and low airflow, generally prevents proper ventilation. As a result, the foam material can exhibit an uncomfortable level of heat to the user after a period of time.

[0004] In addition, the properties of the foam layers utilized in mattresses can change across the lifetime of owning the mattress, from the point of selecting the mattress until the mattress is eventually replaced. In particular, it has been noticed by consumers that the mattress they select when testing mattresses on the showroom floor may have a firmness that differs, at least somewhat, from the firmness of the mattress that ultimately is delivered to their home after they purchase the mattress. Commonly, the consumer finds that the mattress delivered to their home is more firm than the mattress they tested on the showroom floor. Additionally, over time the firmness of the mattress may change. As the consumer uses the mattress, the mattress may develop areas where the mattress is less firm than in other areas. Thus, over time the sleeping surface(s) of the mattress can have an inconsistent feeling, one where the firmness of the mattress varies or is perceived to vary.

[0005] Mattress manufacturers have circumvented this problem by educating the consumer about the nature of foam and informing them that they should expect the firmness of their newly purchased mattress to change over time. However, this approach fails to address the underlying reasons for the phenomenon and does not provide the consumer with a reliable estimate about how much the firmness of their new mattress is likely to change.

BRIEF SUMMARY

[0006] Disclosed herein are bedding products including a pre-conditioned three- dimensional polymeric fiber matrix. In one or more embodiments, a pre-conditioned three dimensionally polymeric fiber matrix layer for a mattress construction includes an extruded three dimensional polymeric fiber layer having constant length, width and height dimensions, the extruded three dimensional polymeric fiber layer including randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer, wherein a portion of the coupling points and the randomly oriented polymer fibers are broken so as to change a mechanical property of the pre-conditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning.

[0007] In one or more embodiments, a mattress includes at least one pre-conditioned three dimensionally polymeric fiber matrix layer including a three dimensional polymeric fiber layer having constant length, width and height dimensions, the extruded three dimensional polymeric fiber layer including randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer, wherein a portion of the coupling points and the randomly oriented polymer fibers are broken so as to change a mechanical property of the pre-conditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning.

[0008] The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0009] Figure (FIG.) 1 schematically illustrates a partial cross sectional view of a three-dimensional polymeric fiber matrix layer;

[0010] FIG. 2 schematically illustrates an exemplary system for pre-conditioning a three-dimensional polymeric fiber matrix layer;

[0011] FIG. 3 schematically illustrates an exemplary system for pre-conditioning a three-dimensional polymeric fiber matrix layer; [0012] FIG. 4 depicts an alternative system for pre-conditioning a three-dimensional polymeric fiber matrix layer;

[0013] FIG. 5 schematically illustrates an exemplary mattress including a preconditioned three-dimensional polymeric fiber matrix layer.

[0014] FIG. 6 schematically illustrates an exemplary mattress including a preconditioned three-dimensional polymeric fiber matrix layer.

[0015] FIGS 4 and 5 depict a top-down view (top) and side view (bottom) of a mattress 200, respectively, according to an embodiment of the invention. The mattress 200 includes a mattress core 202 and at least one three dimensional PLA fiber matrix layer 204 disposed upon the mattress core 202 to provide a sleeping surface. Portions 206 and 208 of the three dimensional PLA matrix layer 204 may be processed differently. For example, portion 208 of the three dimensional PLA matrix layer 204 may be pre-conditioned, whereas portion 206 is not pre-conditioned. This results in a mattress where certain portions of the mattress can be firmer or softer, and can be tailored to match a user's sleeping posture. In other embodiments, different portions of the three dimensional PLA matrix layer 204 may be pre-conditioned to different extents. For example, (or stretched) a certain amount to provide a particular firmness, and another section of the three dimensional polymer matrix layer 204 may be compressed or stretched by a different amount to provide firmness. Optionally, a three dimensional PLA matrix layer 204 may be pre-conditioned in more than two portions, and each portion may be pre-conditioned to provide a different firmness.

[0016] FIG 6. schematically illustrates a mattress 300 including a lower base layer 302, a three dimensional polymer fiber matrix layer 304, and at least one upper foam layer 306, wherein the three dimensional PLA fiber matrix layer 304 is intermediate to the base layer 302 and the upper foam layer 304.

DETAILED DESCRIPTION

[0017] The present disclosure overcomes the problems noted in the prior art by providing a mattress with one or more pre-conditioned three-dimensional polymeric matrix fiber layers. The location of the one or more pre-conditioned three-dimensional polymeric matrix fiber layers is not intended to be limited. In one or more embodiments, the preconditioned three-dimensional polymeric matrix fiber layer or layers can be disposed in proximity to the surface. [0018] In one or more other embodiments, the pre-conditioned three dimensional polymeric matrix fiber layers is utilized as a transition layer between the base foam layer and one or more foam layers, e.g., polyurethane foam layers, latex foam layers, viscoelastic foam layers, or the like, in an all-foam mattress construction or between the innercore and one or more foam layers in a hybrid mattress construction that can further include a bladder, coil springs or the like as the base layer.

[0019] The three dimensional polymeric fiber matrix layer is generally formed via extrusion processing that results in a three dimensional random polymer orientation with varied contact points between fibers serving as bonding points to provide rigidity and structure to the three dimensional layer. The three dimensional polymeric fiber matrix layer by itself is subject to fatigue in the shear direction such as may occur when a user rolls from side to side on the mattress including the three dimensional polymeric layer. As a result, compaction of the three dimensional polymeric layer can occur as a function of use, which manifests itself over time as a change in firmness and height loss. To minimize property changes to the three dimensional polymeric matrix layer as a function of use, the three dimensional polymeric matrix layer is subjected to a pre-conditioning process that breaks the weaker bonds and/or structurally weaker fibers within the three dimensional polymer matrix layer.

[0020] Turning now to FIG. 1, there is depicted a three dimensional polymeric matrix layer prior to pre-conditioning generally designated by reference numeral 10. The three dimensional polymeric matrix layer 10 includes randomly oriented fibers 12 defining a significant number of voids 14, i.e., a relatively large amount of free space per unit area, wherein the free space is defined as an area not occupied by a polymer strand and is also referred to herein as voids. The three dimensional polymeric matrix layer 10 includes a plurality of bonding points 16 at points of intersection between the randomly oriented fibers.

[0021] Generally, the three dimensional polymeric matrix layer 10 is formed by first extruding the desired three dimensional polymeric fiber layer. Granules, pellets, chips, or the like of a desired polymer are fed into an extrusion apparatus, i.e., an extruder, at an elevated temperature and pressure, which is typically greater than the melting temperature of the polymer. The polymer, in melt form, is then extruded through a die, which generally is a plate including numerous spaced apart apertures of a defined diameter, wherein the placement, density, and the diameter of the apertures can be the same or different throughout the plate. When different, the three dimensional polymeric fiber layer can be made to have different zones of density, e.g., sectional areas can have different amounts of free volume per unit area. For example, the three dimensional polymeric fiber layer can include a frame-like structure, wherein the outer peripheral portion has a higher density than the inner portion; or wherein the three dimensional polymeric fiber layer has a checkerboard-like pattern, wherein each square in the checkerboard has a different density than an adjacent square; or wherein the three dimensional polymeric fiber layer has different density portions corresponding to different anticipated weight loads of a user thereof. The various structures of the three dimensional polymer fiber layer are not intended to be limited and can be customized for any desired application. In this manner, the firmness, i.e., indention force deflection, and/or density of the three dimensional polymeric fiber layer can be uniform or varied depending on the die configuration and conveyor speed.

[0022] The polymer is extruded into a cooling bath which results in entanglement and bonding of polymeric fibers through entanglement. Concurrently, the continuously extruded, cooled polymeric matrix is pulled onto a conveyor. The rate of conveyance and cooling bath temperature can be individually varied to further vary the thickness and density of the three dimensional polymeric fiber layer. Generally, the thickness of the three-dimensional polymeric fiber matrix layer by itself can be extruded as a full width mattress material at thicknesses ranging from about 1 to about 6 inches and can be produced to topper sizes or within roll form. However, thinner or thicker thicknesses could also be used as well as wider widths if desired. The pre-conditioned three-dimensional polymeric fiber layer can have a thickness ranging from 0.5 to 5.9 inches.

[0023] Suitable extruders include, but are not limited to continuous process high shear mixers such as: industrial melt-plasticating extruders, available from a variety of manufacturers including, for example, Cincinnati-Millicron, Krupp Werner & Pfleiderer Corp., Ramsey, N.J. 07446, American Leistritz Extruder Corp.; Somerville, N.J. 08876; Berstorff Corp., Charlotte, N.C.; and Davis- Standard Div. Crompton & Knowles Corp., Paweatuck, Conn. 06379. Kneaders are available from Buss America, Inc.; Bloomington, III; and high shear mixers alternatively known as Gelimat™ available from Draiswerke G.m.b.H., Mamnheim-Waldhof, Germany; and Farrel Continuous Mixers, available from Farrel Corp., Ansonia, Conn. The screw components used for mixing, heating, compressing, and kneading operations are shown and described in Chapter 8 and pages 458-476 of Rauwendaal, Polymer Extrusion, Hanser Publishers, New York (1986); Meijer, et al., "The Modeling of Continuous Mixers. Part 1 : The Corotating Twin-Screw Extruder", Polymer Engineering and Science, vol. 28, No. 5, pp. 282-284 (March 1988); and Gibbons et al, "Extrusion", Modern Plastics Encyclopedia (1986- 1987). The knowledge necessary to select extruder barrel elements and assemble extruder screws is readily available from various extruder suppliers and is well known to those of ordinary skill in the art of fluxed polymer plastication.

[0024] The extruded polymer fiber structure may be formed from polyesters, polyethylene, polypropylene, nylon, elastomers, copolymers and its derivatives, including monofilament or bicomponent filaments having different melting points. In one example, the polymer fiber structure is an engineered polyester fiber material. An exemplary polymer fiber structure according to this disclosure is a core polyester fibers that are sheathed in a polyester elastomer binder.

[0025] The engineered fibers can be solid or hollow and have cross-sections that are circular or triangular or other cross sectional geometries, e.g. tri-lobular, channeled, and the like. Another type of polyester fiber has an entangled, spring-like structure. During manufacturing the polymeric fiber structure is heated by extrusion to interlink the fibers to one another to provide a more resilient structure. Fibers may be randomly oriented or directionally oriented, depending on desired characteristics. Such processes are discussed in U.S. Pat. No. 8,813,286, entitled Tunable Spring Mattress and Method for Making the Same, the entirety of which is herein incorporated by reference.

[0026] The fibers and their characteristics are selected to provide desired tuning characteristics. One measurement of "feel" for a cushion is the indentation-force-deflection, or IFD. Indentation force- deflection is a metric used in the flexible foam manufacturing industry to assess the "firmness" of a sample of foam such as memory foam. To conduct an IFD test, a circular flat indenter with a surface area of 323 square centimeters (50 sq. inches - 8" in diameter) is pressed against a sample usually 100 mm thick and with an area of 500 mm by 500 mm (ASTM standard D3574). The sample is first placed on a flat table perforated with holes to allow the passage of air. It then has its cells opened by being compressed twice to 75% "strain", and then allowed to recover for six minutes. The force is measured 60 seconds after achieving 25% indentation with the indenter. Lower scores correspond with less firmness; higher scores with greater firmness. The IFD of the three dimensional polymer fiber matrix layer tested in this manner and configured for use in a mattress has an IFD ranging from 5 to 25 pounds-force. The density of the three dimensional polymeric fiber matrix layer prior to pre-conditioning ranges from 1.5 to 6 lb/ft3. Subsequent to preconditioning, the three dimensional polymeric fiber matrix layer can have a density of 1.6 to 7 lb/ft3 and an IFD of 4 to 24.9 pounds-force. [0027] FIG. 2 depicts one embodiment of a system 50 capable of processing a three dimensional polymeric fiber matrix layer 52 to provide a more consistent and uniform firmness or hardness across the surface 54 of the three dimensional polymeric fiber matrix layer 52 and for its usable life as a layer in a mattress. In particular, FIG. 2 shows a mattress being made with a three dimensional polymeric fiber matrix layer 52 fitted on top of a mattress core 54. The mattress core 54 is seated on a table 60 above a moving platen 62. The platen 62 is capable of moving back and forth from the foot of the mattress to the head of the mattress as indicated by arrow 65 and at the same time, a mechanical arm 64 moves up and down as indicated by arrow 66. The mechanical arm 64 is capable of cyclically processing the three dimensional polymeric fiber matrix layer 52 to apply a mechanical force. The amount of mechanical force applied is selected to adjust a mechanical characteristic such as the IFD of the three dimensional polymer fiber matrix layer 52. The platen 62 carried on the mechanical arm 64 can move across the entire surface of the mattress, thereby processing the mattress across substantially its full length and width. This provides for a more consistent firmness across the full length and width of the mattress. In other embodiments, the three dimensional polymeric fiber matrix layer 52 may be first processed individually, without the mattress core 54, and then disposed on the mattress core to provide a conditioned mattress assembly.

[0028] In one or more embodiments, the platen 64 can sized to be substantially similar to the sleeping area of the mattress and/or the three dimensional polymeric fiber matrix layer 52. In such embodiments, the system 50 may be used to pre-condition a substantial portion of the mattress. Moreover, in such embodiments, the system 50 may be used to pre-condition the head, body and foot portions of the mattress surface simultaneously. In still other embodiments, the system 50 may be configured as desired depending on the nature of the preconditioning. For example, the platen 62 may be sized and shaped to selectively pre-condition either a middle portion or edge portion or both of a mattress, foam pad, and/or polymer matrix. In another example, the system 50 may be configured with a plurality of platens 63 for pre-conditioning different portions of the mattress by applying similar or different loads. In certain embodiments, the platen 62 may be moveable along the length or width of the mattress and equipped with a cylindrical roller such that the platen 62 may roll along the surface of the mattress to progressively compress the mattress and/or the three dimensional polymeric fiber matrix layer 52. Generally, in other embodiments and practices, it could be that the device shown in FIG. 2 merely processes selected portions and areas of the three dimensional polymeric fiber matrix layer 52. In certain embodiments, the mattress may be posturized such that the mattress may be configured with a plurality of zones of varying firmness. In such embodiments, the mattress may be posturized with selected zones having different firmnesses from other zones to promote natural alignment of the S -curve of your spine by adding extra support in the lower back and under the knees or to provide varying firmness zones for partners that sleep on the same mattress but desire different firmness. It will be apparent to those with skill in the art that the areas processed on the three dimensional polymeric fiber matrix layer 52 will depend on the application and can vary as desired. In certain embodiments, more three dimensional polymeric fiber matrix layer (not shown) may be further disposed on the mattress to provide multiple layers of foam. Optionally, one or more of these additional three dimensional polymeric fiber matrix layer 52 may also be pre-conditioned by stressing, compression, and/or stretching as described in this application, to provide a mattress with multiple layers of pre-conditioned foam or polymer matrix. Still further, it should be apparent that the mattress may include additional layers of foam, coil springs, or the like.

[0029] FIG. 3 depicts an alternate system 100 for processing a three dimensional polymeric fiber matrix layer 52. In the depicted embodiment, a pair of counter-rotating rollers 102, 104 apply a force across the full length and width of the three dimensional polymeric fiber matrix layer 52. The rollers can optionally be placed into the extrusion line, the cutting line, mattress assembly line, or the shipping assembly line so that newly manufactured three dimensional polymeric fiber matrix layer 52 is processed as it is being prepared in the factory. These and other suitable systems for preconditioning the three dimensional polymeric matrix layer of the present disclosure are further disclosed in US Pat. No. 7,690,096, incorporated herein by reference in its entirety.

[0030] FIG. 4 depicts a top-down view (top) and a side view (bottom) of a mattress 200 according to an embodiment of the invention. The mattress 200 includes a mattress core 202 and a three dimensional polymeric fiber matrix layer 204 disposed upon the mattress core 202 to provide a sleeping surface. Portions 206 and 208 of the three dimensional polymeric matrix layer 204 may be processed differently. For example, portion 208 of the three dimensional polymer matrix layer 204 may be pre-conditioned, whereas portion 206 is not preconditioned. This results in a mattress where certain portions of the mattress can be firmer or softer, and can be tailored to match a user's sleeping posture. In other embodiments, different portions of the three dimensional polymeric matrix layer 204 may be pre-stressed to different extents. For example, one section of the three dimensional polymer matrix layer 204 may be compressed (or stretched) a certain amount to provide a particular firmness, and another section of the three dimensional polymeric matrix layer 204 may be compressed or stretched by a different amount to provide a different firmness. Optionally, a three dimensional polymeric matrix layer 204 may be pre-conditioned in more than two portions, and each portion may be pre-conditioned to provide a different firmness.

[0031] FIG. 5 schematically illustrates a mattress 300 including a lower base layer 302, a three dimensional polymeric fiber matrix layer 304, and at least one upper foam layer 306, wherein the three dimensional polymeric fiber matrix layer 304 is intermediate to the base layer 302 and the upper foam layer 304.

[0032] Generally, the thickness of the lower base layer 302 is within a range of 4 inches to 10 inches, with a range of about 6 inches to 8 inches thickness in other embodiments, and a range of about 6 to 6.5 inches in still other embodiments. The lower base layer can be formed of open or closed cell foams, including without limitation, viscoelastic foams, latex foam, conventional polyurethane foams, and the like.

[0033] The lower base layer 302 can have a density of 1 pound per cubic foot (lb/ft3) to 6 lb/ft ³ . In other embodiments, the density is 1 lb/ft ³ to 5 lb/ft3 and in still other embodiments, from 1.5 lb/ft ³ to 4 lb/ft ³ . By way of example, the density can be about 1.5 lb/ft ³ . The indention force deflection (IFD), is within a range of 20 to 40 pounds-force, wherein the hardness is measured in accordance with ASTM D-3574.

[0034] Alternatively, the lower base layer 302 can be a coil spring innercore disposed within a cavity defined by a bucket assembly, wherein the bucket assembly includes a planar base layer and side rails disposed about a perimeter of the planar base layer.

[0035] The at least one upper foam layer 306 defines a cover panel overlying the three dimensional polymeric matrix fiber layer 304. The cover panel can be formed from one or more viscoelastic foam and/or non- viscoelastic foam layers depending on the intended application. The foam itself can be of any open or closed cell foam material including without limitation, latex foams, natural latex foams, polyurethane foams, combinations thereof, and the like. The cover panel has planar top and bottom surfaces. The thickness of the cover panel is generally within a range of about 0.5 to 2 inches in some embodiments, and less than 1" in other embodiments so as to provide the benefits of motion separation and increased airflow from the underlying foam layer 104. The density of the at least one upper foam layer 306 is within a range of 1 to 5 lb/ft ³ in some embodiments, and 2 to 4 lb/ft ³ in other embodiments. The hardness is within a range of about 10 to 20 pounds-force in some embodiments, and less than 15 pounds- force in other embodiments. In one embodiment, the cover panel is at a thickness of 0.5", a density of 3.4 lb/ft ³ , and a hardness of 14 pounds-force.

[0036] The various multiple stacked mattress layers 302, 304, and 306 may be adjoined to one another using an adhesive or may be thermally bonded to one another or may be mechanically fastened to one another as may be desired for different applications.

[0037] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.