A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Any superimposed central portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).

An internal tensioning structure for use in an inflatable product fulfills the basic function of maintaining two adjacent inflatable surfaces in a desired geometric arrangement when the inflatable product is pressurized. The tensioning structure is formed by connecting a pair of plastic strips sheets via spaced-apart strands, such as strings or wires. When pulled taut, the strands provide a high tensile strength between the two opposed plastic strips. At the same time, the plastic strips facilitate a strong, long-lasting weld between the tensioning structure and the inflatable product.

A three-dimensional component is produced in a simplified molding operation. Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. Boards can be formed by laminating two or more blanks together and/or by laminating the blanks with other materials, including non-expendable materials. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. In addition, the boards or blanks may be cut to create desired shapes of parts that can be placed in the mold.

A plant for the continuous vulcanisation of mixtures of natural or synthetic latex inside a plurality of vulcanisation moulds aligned close to each other, each including: a base and a lid able to be removably coupled; an advancing mechanism for advancing the moulds along guides inside a vulcanising oven; and a sprayer for spraying the mixture inside the bases before entry into the vulcanising oven. The plant includes: an assembly set and a disassembly set of the moulds, belonging respectively to the input station and to the output station of the vulcanising oven; a first transport mechanism for transferring each base from the disassembly set to the assembly set; a second transport mechanism for transferring each lid from the disassembly set to the assembly set. The vulcanising oven includes a tunnel with a radiofrequency set for vulcanising the mixture.

Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.

A welding process of an inflatable product is provided that includes using isolating members between first and second portions of weldable tensioning members to resist the first and second portions of the weldable tensioning structures being welded together during welding of the first portions to a first sheet of weldable material and welding of the second portions to a second sheet of weldable material.

A cover for a cushion includes a first panel, a second panel, and a primary receptacle defined between the first panel and the second panel. The primary receptacle may receive a primary cushioning element, such as a pillow, a pillow insert, or a fill material. At least one of the first panel and the second panel includes a secondary cushioning element. The secondary cushioning element may be defined from a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls that in turn define an array of open cells or columns. Each cell or column may have a hexagonal shape, imparting the array of open cells or columns with a honeycomb appearance. Methods for assembling a primary cushioning element with such a cover are also disclosed.

A bedding product having a cooling layer and a method therefor. The bedding product has a gel layer having an outside surface, a bonding surface opposite the outside surface, and a perimeter. A memory foam layer surrounds the perimeter and is disposed on the bonding surface. A textile layer having a first rectangular portion and a second rectangular portion affixed on a perimeter thereof to the first rectangular portion retains the gel layer and memory foam layer therebetween. The textile layer has a cooling surface, an opposing surface opposite the cooling surface, and at least one vent disposed adjacent to an edge portion of the first or second rectangular portion. The gel layer contains a plurality of hexagonal prism-shaped peaks and valleys on the outside surface thereof, and the gel layer and memory foam layer have a plurality of air conduits for air flow communication with the vent.

A hospital bed includes a sleep deck having an upper portion, a middle portion, and a lower portion each defining a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between the upper portion and the middle portion. A mattress is disposed on the sleep deck. An outer mattress shell encases the mattress and includes a fold defined by a weld. A mattress retention assembly is coupled to the outer mattress shell. The mattress retention assembly includes at least one of a first magnet and a second magnet selectively coupling the mattress to the sleep deck, a portion of the mattress retention assembly extends between the outer mattress shell and the sleep deck, an affixing member disposed on the outer mattress shell, and a retention ridge extending through the sleep deck.

A method of making a mesh cushion. The method includes extruding a material through a plurality of filament forming openings in at least one die plate to form a plurality of filaments. The filaments may be at least partially submerged into a fluid to cool and harden the filaments into the mesh cushion.