A cushion having a fibrous foam architecture. The cushion has a trim cover and a number of fibrous layers attached to the trim cover. One or more structural properties of a fibrous layer can be controlled to differ from that of other layers.

A panel body (1) according to the present invention includes a cushioning layer (51) that contains a fibrous base material (2A) and a cushioning layer (52) that contains a fibrous base material (2B). The first cushioning layer (51) and the second cushioning layer (52) respectively include heat-joining layers (10 and 12) which contain base materials (2A and 2B) and joining materials having lower melting points than the base materials (2A and 2B), and surface layers (20 and 22) which are bonded to surfaces of the heat-joining layers (10 and 12) and are formed of the base materials (2A and 2B).

A panel body (1) according to the present invention includes a cushioning layer (51) that contains a fibrous base material (2A) and a cushioning layer (52) that contains a fibrous base material (2B). The first cushioning layer (51) and the second cushioning layer (52) respectively include heat-joining layers (10 and 12) which contain base materials (2A and 2B) and joining materials having lower melting points than the base materials (2A and 2B), and surface layers (20 and 22) which are bonded to surfaces of the heat-joining layers (10 and 12) and are formed of the base materials (2A and 2B).

A fiber cushion body comprises a first portion in which fibers have a preferential orientation along a first direction and at least a second portion having a fiber orientation and/or density different from the first portion. The fiber cushion body is processed using laser radiation to form a laser cut or laser weld.

A fiber cushion body comprises a first portion in which fibers have a preferential orientation along a first direction and at least a second portion having a fiber orientation and/or density different from the first portion. The fiber cushion body is processed using laser radiation to form a laser cut or laser weld.

A process and apparatus for manufacturing a mattress generally includes an automated foam layer placement apparatus for accurately securing one or more foam layers onto an innercore unit and bucket assembly.

A process and apparatus for manufacturing a mattress generally includes an automated foam layer placement apparatus for accurately securing one or more foam layers onto an innercore unit and bucket assembly.

A partially foam encased pocketed spring assembly is made in a fully automated assembly machine. A first foam rail is introduced into the assembly machine and glued to upper and lower substrate webs. A first string of pocketed springs is then glued to a side surface of the first foam rail between upper and lower substrate webs and glued to the upper and lower substrate webs. Additional strings are joined together to create a pocketed spring interior. A second foam rail is then introduced into the assembly machine and glued to an outer string and to the upper and lower substrate webs to create a core. Third and fourth foam rails are glued to the core.

A partially foam encased pocketed spring assembly is made in a fully automated assembly machine. A first foam rail is introduced into the assembly machine and glued to upper and lower substrate webs. A first string of pocketed springs is then glued to a side surface of the first foam rail between upper and lower substrate webs and glued to the upper and lower substrate webs. Additional strings are joined together to create a pocketed spring interior. A second foam rail is then introduced into the assembly machine and glued to an outer string and to the upper and lower substrate webs to create a core. Third and fourth foam rails are glued to the core.

A partially foam encased pocketed spring assembly is made in a fully automated assembly machine. A first foam rail is introduced into the assembly machine and glued to upper and lower substrate webs. A first string of pocketed springs is then glued to a side surface of the first foam rail between upper and lower substrate webs and glued to the upper and lower substrate webs. Additional strings are joined together to create a pocketed spring interior. A second foam rail is then introduced into the assembly machine and glued to an outer string and to the upper and lower substrate webs to create a core. Third and fourth foam rails are glued to the core.