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 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 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.

The disclosure provides a cushion including an outer cover defining an interior cavity, and inner filler material disposed within the interior cavity. The inner filler material may comprise at least one molded block of polyurethane foam. The outer cover and/or the inner filler material may be porous to at least water. The cushion further includes a waterproof coating to the outer surface the inner filler material and forming waterproof seal extending entirely thereabout after curing. The waterproof coating comprises butyl acrylate within the range of 17-32 wt %, styrene within the range of 13-26 wt %, and deionized water within the range of 42-70 wt % prior to curing. The waterproof coating may further include auxiliary components within the range of 0.5-8 wt % prior to curing. The auxiliary components may include acrylic acid, sodium lauryl sulfate, an emulsifier component, ammonium peroxydisulfate, sodium bicarbonate, sodium phosphate, tertiary and tributyl phosphate.

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 system for controlling a fiber orientation and/or a density of fibers in a mold comprises at least one nozzle configured to define a location at which gas is withdrawn from the mold. A displacement mechanism is configured to effect a relative displacement between the at least one nozzle and the mold.

A system for controlling a fiber orientation and/or a density of fibers in a mold comprises at least one nozzle configured to define a location at which gas is withdrawn from the mold. A displacement mechanism is configured to effect a relative displacement between the at least one nozzle and the mold.