A mattress including a base layer, at least one intermediary layer, and a top layer. The base layer is constructed from a foam material defining an Indentation Level Deflection (ILD) Rating from 25 to 35 pounds, and defines a thickness of between four and eight inches (4-8), and having a density from 1 to 4 lb/ft.sup.3. Each intermediary layer is constructed from a foam material defining an ILD Rating of between 10 and 25 and defines a thickness from 1.5 to 3, and having a density from 2 to 4 lb/ft.sup.3. A top layer is fabricated from a vertically-oriented synthetic memory fiber blend comprised of bi-copolymer fibers and fibers having spring-like molecular structure. The top layer defines a thickness of between 0.75 and 1.25 and a weight of between about 200 to about 500 grams per square yard. A cover layer may be disposed above said top layer, the cover layer being fabricated from a selected foam material, and defining a thickness of up to about one inch. A cover member configured to closely and selectively receive the various layers of the mattress may be provided. The cover member may be being provided with at least one handle for assisting in movement and transport of said mattress.

Mattress assemblies including fiber panels generally include bicomponent fibers including optically active particles within a core thereof. The bicomponent fibers can be treated with a fire retardant or untreated and blended with fire retardant fibers. The bicomponent fibers are configured to transform radiant body heat of an end user.

A manufacturing apparatus and manufacturing method for manufacturing a three-dimensional filaments-linked structure includes: divided weight information acquisition means which records divided weight information acquired by dividing weight distribution in a height direction of a person in a height axis direction, in correlation with a distance from a top of a head of the person; and three-dimensional linked structure formation means which tangles and fuses filaments of a thermoplastic resin material extruded from an extruder in a three-dimensional net shape, and forms a three-dimensional filaments-linked structure which is long in a product streaming direction, and the three-dimensional linked structure formation means includes filament density control means which controls filament density in the product streaming direction based on the divided weight information. As a result of the configuration, it is possible to promptly, reliably, and efficiently manufacture products with desired specifications for customers who request products with made-to-order specifications.

The present invention provides a network structure having excellent repeated compression durability, a low repeated compression residual strain and a high hardness retention after repeated compression. A network structure made of a three-dimensional random loop bonded structure obtained by forming random loops with curling treatment of a continuous linear structure including at least one thermoplastic elastic resin selected from the group consisting of a polyolefin-based thermoplastic elastomer, an ethylene-vinyl acetate copolymer, a polyurethane-based thermoplastic elastomer and a polyamide-based thermoplastic elastomer, the continuous linear structure having a fineness of not less than 100 dtex and not more than 60000 dtex, and by making each loop mutually contact in a molten state, wherein The network structure has an apparent density of 0.005 g/cm.sup.3 to 0.20 g/cm.sup.3, a 50%-constant displacement repeated compression residual strain of not more than 15%, and a 50%-compression hardness retention after 50%-constant displacement repeated compression of not less than 85%.

A mattress in which a vibration is unlikely to be transmitted between different cushion members is provided. The mattress includes a mattress cushion on which a plurality of persons can lie in a left/right direction, the mattress cushion includes a plurality of cushion members that can be separated in the left/right direction, each of the cushion members is formed with a filament three-dimensional bonded member that includes a plurality of filaments, and includes a contact surface that is in contact with another cushion member adjacent to the cushion member and ends of the filaments of the cushion member do not enter the other cushion member adjacent to the cushion member.

By taking into account the difficulty in smoothly bending along the shape of, for example, a care bed, there is provided a three-dimensional net-like structure made from polyethylene having a swelling ratio dependent on a shear rate such as to be 0.93 to 1.16 at a shear rate of 24.3 sec.sup.1 and 1.15 to 1.34 at a shear rate of 608 sec.sup.1 and having an MFR of 3 to 35 g/10 min and a density of 0.82 to 0.95 g/cm.sup.3 and configured to have a spring structure of filaments randomly brought into contact with and tangled with one another, have a three-dimensional striped sparse-dense configuration in a lateral direction relative to an extrusion direction. The swelling ratio is shown as D.sub.2/D.sub.1 against shear rate when a molten thermoplastic resin is extruded to filaments from a capillary having a tube inner diameter D.sub.1 of 1.0 mm and a length of 10 mm and D.sub.2 denotes a diameter of cross section of the filaments extruded and cooled down.

By taking into account the difficulty in smoothly bending along the shape of, for example, a care bed, there is provided a three-dimensional net-like structure made from polyester having a swelling ratio dependent on a shear rate such as to be 1.10 to 1.38 at a shear rate of 60.8 sec.sup.1 and 1.17 to 1.43 at a shear rate of 608 sec.sup.1 and having an MFR of 3 to 35 g/10 min and a density of 1.01 to 1.60 g/cm.sup.3 and configured to have a spring structure of filaments randomly brought into contact with and tangled with one another, have a three-dimensional striped sparse-dense configuration in a lateral direction relative to an extrusion direction. The swelling ratio is shown as D.sub.2/D.sub.1 against shear rate when a molten thermoplastic resin is extruded to filaments from a capillary having a tube inner diameter D.sub.1 of 1.0 mm and a length of 10 mm and D.sub.2 denotes a diameter of cross section of the filaments extruded and cooled down.

A method and device for carrying out the method of converting waste such as thermally bonded polyester fiber to bed cushioning. Such waste is fed to a fiber lofter which forms lofted fiber. The lofted fiber is pneumatically transferring to a hopper, and from the hopper to an injector, the injector having a lofted fiber input nozzle and output nozzle, the output nozzle being a low friction tube.

A mattress pad for supporting a human body includes an upper layer, a lower layer, and a wadding layer therebetween including three distinct zones arranged along the length of the pad for varying support of the human body; the first zone is configured to support a head portion and a neck portion; the second zone is configured to support an upper body portion and a lumbar portion; and the third zone is configured to support a lower back portion and leg portion wherein thickness and length in these zones varies for providing the varying support.

A cushion filler material including a plurality of loose pieces of filler material and a plurality of gel material pieces is disclosed. The cushion filler material may be used in, for example, bedding products and furniture cushions.