A mattress including a stretchable flame-retardant textile cap incorporating a top panel of flame retardant material operatively connected to a stitch-bonded flame retardant textile skirting with machine direction stretch and recovery properties disposed over a resilient mattress core to provided flame barrier protection to the mattress core.

A bed system includes microclimate control capabilities for providing quality sleep experience. The bed system can include a microclimate control subsystem configured to supply conditioned air (e.g., heated or cooled air) to a mattress, or draw ambient air from the mattress, to achieve a desired temperature at the top of the mattress. Utilizing supply of conditioned air to provide air at desired temperature to the mattress system, or utilizing air suction to drain heat away from the mattress system, can provide precise microclimate control at the mattress, thereby permitting conformable sleep.

It is an object of the present invention to provide a fabric, a fabric body, and a seat that exhibit excellent appearance, sitting comfort, and air permeability, and exhibit an excellent flame retardancy. Provided is a fabric, comprising 50% by mass or more of monofilament, wherein the monofilament is a core-sheath composite fiber having a core and a sheath, wherein the core is contained in 60 to 90% by volume with respect to the core-sheath composite fiber and contains a first flame retardant and a polyester elastomer, and wherein the sheath is contained in 10 to 40% by volume with respect to the core-sheath composite fiber and consists of polyester excluding the polyester elastomer of the core.

A stretchable flame barrier panel including an interior stretch zone having elastomeric yarns extending across a fibrous base layer of textile fibers and optionally substantially stable lateral selvage zones outboard of the interior stretch zone. In a finished state, the interior stretch zone has substantial stretch and recovery in both the machine direction and the cross-machine direction.

A mattress wherein a plurality of independent yarn based fire barrier fabrics encases a plurality of distinct and unattached interior core structures. The plurality of interior core structures include at least a detached and internally flippable upper comfort layer assembly with a plurality of non-homogeneous foams or filling materials encased in a yarn-based fire barrier fabric and a lower, interiorly disposed support core structure with resilient filling materials encased in a yarn-based fire barrier fabric and a fabric cover. The detachable and internally flippable upper comfort layer assembly may be contained in a user accessible compartment that is fashioned into an outer cover assembly.

A mattress or mattress topper includes a cushioning element having an elastomeric material forming intersecting buckling walls that define hollow columns, and a knitted fabric disposed over the cushioning element and configured to move independently of the buckling walls. The elastomeric material includes an elastomeric polymer and a plasticizer. The knitted fabric includes a first layer of stretchable material; a second layer of stretchable material; and a layer of stretchable fill material between the first layer of stretchable material and the second layer of stretchable material. The first layer of stretchable material is knitted together with the second layer of stretchable material as a unitary sheet of fabric including the layer of stretchable fill material. A method of forming a mattress or mattress topper includes disposing a knitted fabric over a cushioning element comprising intersecting buckling walls and configuring the knitted fabric to move independently of the buckling walls.

A mattress that efficiently provides low pressure and alignment to achieve restful and less fragmented sleep. The mattress supports a recumbent body. The mattress comprises a composite and a cover encapsulating the composite. The composite includes a performance layer and a core layer. The performance layer includes a shoulder section, a thoracic section and a hip section for location at different longitudinal positions corresponding to the shoulder region, the thoracic region and the hip region of the recumbent body. The shoulder section, the thoracic section and the hip section have different displacement parameters to match the body displacements in the shoulder region, the thoracic region, and the hip region for alignment of the body with low body pressure. A core layer supports the performance layer.

A mattress assembly includes a tub including rails and a base with the tub defining an interior cavity bound by the rails and the base, a plurality of non-laminated and rearrangeable layers positioned within the interior cavity to provide both support and comfort levels within the mattress assembly with each layer including at least one of a layer cover or a layer foam, and a cover system including a removable cover allowing selective access to the plurality of layers and the interior cavity and selectively compressing the plurality of layers within the tub, where the cover system includes a first zipper and a second zipper coupling the removable cover to the tub, and the first zipper and the second zipper meet at a central portion of a front side of the mattress assembly.

The composite fabric is suitable as a flame barrier for different articles, such as mattresses, pillows, seats and upholstered furniture and is made from a plurality of joined breathable layers including at least one textile layer and one impervious layer joined including a knitted textile layer made of cellulose fibers of natural renewable origin including at least 50% of cellulose flame-retardant fibers, and the impervious layer including an halogen free plastic material selected among polyurethane or polyester incorporating a known flame-retardant or inhibitor additive.

The present application provides a cushion having a core layer and a quilt support/comfort layer. The core layer may comprise innersprings, foams, air cells, or combinations thereof. The support/comfort layer comprises a sleep layer that simulates a conventional quilted fabric layer. The sleep layer includes a thick, comfort fabric and a backing fabric, which backing fabric may be the same as the thick, comfort fabric. The sleep layer is formed by coupling the thick, comfort fabric to the backing fabric to form a plurality of individual pockets in which micro spring coils are placed. The micro spring coils have less uncompressed height than conventional innerspring coils. The sleep layer coupling is formed by spot coupling without using a metal needle to stitch the layers together. In other words, the spot coupling may comprise an adhesive or weld.