A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft.sup.3 to about 4 lb./ft.sup.3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in.sup.3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in.sup.3, and at least 20% foam pieces having volumes of greater than 2.0 in.sup.3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft.sup.3 to about 2 lb./ft.sup.3.

A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft.sup.3 to about 4 lb./ft.sup.3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in.sup.3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in.sup.3, and at least 20% foam pieces having volumes of greater than 2.0 in.sup.3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft.sup.3 to about 2 lb./ft.sup.3.

A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft.sup.3 to about 4 lb./ft.sup.3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in.sup.3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in.sup.3, and at least 20% foam pieces having volumes of greater than 2.0 in.sup.3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft.sup.3to about 2 lb./ft.sup.3.

A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft.sup.3 to about 4 lb./ft.sup.3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in.sup.3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in.sup.3, and at least 20% foam pieces having volumes of greater than 2.0 in.sup.3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft.sup.3to about 2 lb./ft.sup.3.

A down-fill pillow with a core formed from down feather sheet material pieces used in the fabrication of down insulated products. The size and shape of the pieces do not exceed predetermined sizes. The pieces may have a variety of shapes, such as in block or strip form or of irregular size if formed from trimmings of down sheet material in which is cut patterns for use in the fabrication of insulated articles. The down feather sheet pieces are placed in an envelope formed from one or more down feather sheets and the pieces entangle with one another due to their captive retention in the pillow envelope which restrains the pieces in close contact with one another and limited movement. When the head of a user person is rested on the down-fill pillow, it causes the mixture to compress and mold about the head while remaining entangled and recovering its loft when the head is removed. The method of forming the pillow core by the use of down feather sheet material pieces is also described.

A down-fill pillow with a core formed from down feather sheet material pieces used in the fabrication of down insulated products. The size and shape of the pieces do not exceed predetermined sizes. The pieces may have a variety of shapes, such as in block or strip form or of irregular size if formed from trimmings of down sheet material in which is cut patterns for use in the fabrication of insulated articles. The down feather sheet pieces are placed in an envelope formed from one or more down feather sheets and the pieces entangle with one another due to their captive retention in the pillow envelope which restrains the pieces in close contact with one another and limited movement. When the head of a user person is rested on the down-fill pillow, it causes the mixture to compress and mold about the head while remaining entangled and recovering its loft when the head is removed. The method of forming the pillow core by the use of down feather sheet material pieces is also described.

A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft.sup.3 to about 4 lb./ft.sup.3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in.sup.3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in.sup.3, and at least 20% foam pieces having volumes of greater than 2.0 in.sup.3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft.sup.3to about 2

A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft.sup.3 to about 4 lb./ft.sup.3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in.sup.3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in.sup.3, and at least 20% foam pieces having volumes of greater than 2.0 in.sup.3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft.sup.3to about 2

The present invention provides a thermal insulation filling material and preparation method thereof and a thermal insulation product, and pertains to the field of thermal insulation filling materials. The thermal insulation filling material of the present invention includes: a bulk fibre; and a spherical fibre assembly, where a water-repellent layer is formed on a surface of the bulk fibre and of the spherical fibre assembly, and a weight ratio of the bulk fibre to the spherical fibre assembly is between about 30:70 and about 70:30. The thermal insulation filling material is good in wash durability, and has comprehensive performance such as better blowable processability, quick-drying property, compression-resilience property, and thermal insulation property, etc. The method for preparing the thermal insulation filling material includes: adding a water-repellent agent in the process of gas-flow mixing the bulk fibre and the spherical fibre assembly, and then heating to form a water-repellent layer on the surface of the bulk fibre and of the spherical fibre assembly.

The present invention provides a thermal insulation filling material and preparation method thereof and a thermal insulation product, and pertains to the field of thermal insulation filling materials. The thermal insulation filling material of the present invention includes: a bulk fibre; and a spherical fibre assembly, where a water-repellent layer is formed on a surface of the bulk fibre and of the spherical fibre assembly, and a weight ratio of the bulk fibre to the spherical fibre assembly is between about 30:70 and about 70:30. The thermal insulation filling material is good in wash durability, and has comprehensive performance such as better blowable processability, quick-drying property, compression-resilience property, and thermal insulation property, etc. The method for preparing the thermal insulation filling material includes: adding a water-repellent agent in the process of gas-flow mixing the bulk fibre and the spherical fibre assembly, and then heating to form a water-repellent layer on the surface of the bulk fibre and of the spherical fibre assembly.