SCRIM FIRE SOCK AND METHODS OF MANUFACTURING SAME

CROSS-REFERENCE TO RELATED PATENT APPLICATION

[0001]This application claims the benefit of and priority to U.S. Provisional Application No. 63/733,902, filed Dec. 13, 2024, which is incorporated herein by reference in its entirety and for all purposes.

TECHNICAL FIELD

[0002]Embodiments and aspects of this disclosure relate generally to cushion/cushion members such as mattresses, fabrics for use with mattresses, products including cushion members, and to methods of making and using fabrics and cushion members.

BACKGROUND

[0003]Cushion members are included in mattresses, cushions, shoe inserts, padding, packaging, etc. Cushion members (e.g., a mattress) incorporate layers of cushioning elements (e.g., elastomeric polymers, foam, coils, etc.). The number, order, and composition of the layers of cushioning elements affect the pressure relief and temperature regulation of the cushion member. Cushion members with multiple cushioning element compositions, such as a layer of gel, a layer of foam, and a layer of coil, must be manufactured in compliance with safety regulations. To conform with flammability safety regulations, layers of cushioning element generally require additional fire-retardant treatment such as a physical barrier, commonly referred to as a fire sock. To couple a cushioning element with a fire sock, a layer of fabric of scrim must be bonded in between the layer of cushioning element and the fire-retardant fire sock. It would be advantageous to reduce the manufacturing process and fire-retardant treatment process.

SUMMARY

[0004]One embodiment relates to a cushion member. The cushion member includes a first cushioning layer with a first cushion element, and a cap surrounding the first cushioning layer. The cap includes a fire-retardant material that is configured to bond with the first cushioning layer.

[0005]Another embodiment relates to cap of a cushion member. The cap includes a top panel with a fire-retardant material configured to bond with an elastomeric polymer. The cap also includes a periphery. The periphery extends downwardly from an edge of the top panel.

[0006]Still another embodiment relates to a cushion member. The cushion member includes a plurality of cushioning layers stacked onto each other such that a topmost cushioning layer of the plurality of cushioning layers has a top surface, a bottommost cushioning layer of the plurality of cushioning layers has a bottom surface, and each cushioning layer has a plurality of sides that is tangential to another cushioning layer of the plurality of cushioning layers. The cushion member also includes a cap surrounding the plurality of cushioning layers. The cap includes: a top panel with an inner surface made of fire-retardant material that is configured to bond with the top surface of the topmost cushioning layer, and a periphery that extends downwardly from an edge of the top panel.

[0007]Yet another embodiment relates to method for manufacturing a cushion member. The method includes: providing a cushioning layer made of a gel; positioning the cushioning layer on a guide; positioning a fire-retardant fabric over the cushioning layer and the guide such that the fire-retardant fabric extends beyond the cushioning layer; and heating the fire-retardant fabric, the cushioning layer, and the guide to attach the fire-retardant fabric to the cushioning layer.

[0008]Numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. The described features of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and/or implementations. In this regard, one or more features of an aspect of the invention may be combined with one or more features of a different aspect of the invention. Moreover, additional features may be recognized in certain embodiments and/or implementations that may not be present in all embodiments or implementations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a side view of a cushion member with cushioning layers and a fire-retardant topper, according to an exemplary embodiment.

[0010]FIG. 2 is a side view of cushioning layers and a fire-retardant cap assembled into a cushion member, shown as cushion member 100, according to an exemplary embodiment.

[0011]FIG. 3 is a flow diagram of a process of manufacturing a cushion member or a portion thereof, according to an exemplary embodiment.

[0012]FIG. 4 is a flow diagram of a process of manufacturing a cushion member or a portion thereof, according to an exemplary embodiment.

[0013]FIG. 5 is a perspective view of a scrim material being positioned on a cushioning layer according to the process of FIG. 4, according to an exemplary embodiment.

[0014]FIG. 6 is a perspective view of a template for use in the process of FIG. 4, according to an exemplary embodiment.

[0015]FIG. 7 is a perspective view of fire-retardant cap positioned on a cushioning layer according to the process of FIG. 4, according to an exemplary embodiment.

DETAILED DESCRIPTION

[0016]Referring generally to the FIGURES, a cushion member is shown with a fire-retardant cap according to various embodiments herein. Generally speaking, mattresses may be required to meet fire safety standards set by law and/or industry codes. To comply with these requirements, a mattress may include a fire-retardant layer positioned near the outer surface of the mattress. For example, a separate, fire-retardant “sock” or sleeve may be added around the mattress. However, the addition of the sock or sleeve is another step in the conventional manufacturing process. This additional step may add time and complexity during the manufacturing of a cushion member, such as a mattress. Beneficially, the systems and methods described herein relate to a cushion member (e.g., mattress, etc.) that may be manufactured without this extra step and that may still adhere to one or more various fire standards. As described herein, a cushion member, such as a mattress, may be made at least partially made of a gel, which is coupled to one or more other elements of the cushion member with a scrim. As discussed in further detail below, a fire-retardant cap is integrated into the scrim of the cushion member during the manufacturing process. By integrating the fire-retardant cap into the scrim, fire resistance can be added to the cushion member when the scrim is being added, thereby removing the need for a separate step. Integration of the fire-retardant cap in to the scrim also reduces the total number of layers in the cushion member between a user and the cushioning layers, improving user comfort. These and other features and benefits are described more fully herein below.

[0017]Referring now to FIG. 1, a side view of a cushion member 100 with cushioning layers and a fire-retardant cap 140 is shown, according to an exemplary embodiment. The cushion member 100 includes at least one cushioning layer and a fire-retardant cap 140. The cushion member 100 may be configured for use as a seat cushion, a mattress, a mattress pad, a pillow, a mattress topper, and/or another type of cushion or pad. A cushioning layer may include an elastomeric polymer, such as a gel. In some embodiments, the cushion member 100 may additionally and/or alternatively include foam, springs, and/or other cushioning elements. In the example shown, the cushion member 100 is a mattress. In the example shown, the cushion member 100, a first cushioning layer 110, a second cushioning layer 120, and a third cushioning layer 130 are rectangular in shape. The first cushioning layer 110 may comprise a gel, the second cushioning layer 120 may comprise a foam, and the third cushioning layer 130 may comprise coils. Each cushioning layer includes a top, a plurality of sides extending vertically or substantially vertically downward from the top, and a bottom positioned on an opposite side relative to the top. In some embodiments, a plurality of cushioning layers is arranged in a stack. In such embodiments, a cushioning layer is sewn, ultrasonic welded, glued, fused, and/or otherwise coupled with an adjacent cushioning layer. In the example shown, the bottom of the first cushioning layer 110 directly contacts the top of the second cushioning layer 120 such that the sides of the first cushioning layer 110 is substantially tangential with the sides of the second cushioning layer 120. The bottom of the seconding cushioning layer 120 directly contacts the top of the third cushioning layer 130 such that the sides of the second cushioning layer 120 is substantially tangential with the sides of the third cushioning layer 130. In such example, the sides of the cushioning layers are substantially tangential with one another. In some embodiments, a cushioning layer is shaped differently, for example as an ellipse with a top, a continuous side, and a bottom.

[0018]The gel may be formed of an elastomeric material. Elastomeric materials are described in, As an example, U.S. Pat. No. 5,994,450, titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999 (hereinafter “the '450 Patent”); U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid Block” issued Jun. 21, 2011; U.S. Pat. No. 4,369,284, titled “Thermoplastic Elastomer Gelatinous Compositions” issued Jan. 18, 1983; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014 (hereinafter “the '750 Patent”); the disclosures of each of which are incorporated herein in their entirety by this reference. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, or various similar materials.

[0019]The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). As an example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, TX, under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, TX, under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi component thermoset elastomers.

[0020]The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. As an example, elastomeric materials may include aromatic free food grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, NJ, under the trade names BLANDOL® and CARNATION®.

[0021]In some embodiments, the elastomeric material may have a plasticizer to polymer ratio from about 0.1:1 to about 50:1 by weight. As an example, elastomeric materials may have plasticizer to polymer ratios from about 1:1 to about 30:1 by weight, or even from about 1.5:1 to about 10:1 by weight. In further embodiments, elastomeric materials may have plasticizer to polymer ratios of about 4:1 by weight.

[0022]The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. As an example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase change temperature of the wax or other phase change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase change material may have a melting point from about 20° C. to about 45° C.

[0023]The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long term stability. Antioxidants include, As an example, pentaerythritol tetrakis (3 (3,5 di tert butyl 4 hydroxyphenyl) propionate), commercially available as IRGANOX® 1010, from BASF Corp., of Iselin, NJ or as EVERNOX® 10, from Everspring Corp. USA, of Los Angeles, CA; octadecyl 3 (3,5 di tert butyl 4 hydroxyphenyl) propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris (2,4 di tert butylphenyl) phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of the '450 Patent. The elastomeric material may include up to about 5 wt % antioxidants. For instance, the elastomeric material may include from about 0.10 wt % to about 1.0 wt % antioxidants.

[0024]In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of an elastomeric cushioning element after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, TN, under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.

[0025]In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and/or functional. That is, pigments may provide the elastomeric cushioning element with an appearance appealing to consumers (e.g., a purple color). In addition, an elastomeric cushioning element having a dark color may absorb radiation differently than an elastomeric cushioning element having a light color.

[0026]The elastomeric material may include a material that may substantially return to its original shape after deformation and that may be elastically stretched. The elastomeric material may be rubbery in feel but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials and may have a durometer hardness lower than conventional rubber materials. As an example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.

[0027]The elastomeric material may include any type of gelatinous elastomer. As an example, the elastomeric material may include a melt blend of one part by weight of a styrene ethylene ethylene propylene styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70 weight straight cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.

[0028]In some embodiments, positioned around an outer perimeter of at least some of the cushioning layers (e.g.,, a first cushioning layer 110, a second cushioning layer 120, and/or a third cushioning layer 130) are a plurality of rails. In one configuration, the plurality of rails may be made of a foam with an indentation load deflection (“ILD”) greater than the ILD of the one or more of the cushioning layers. In some embodiments, the plurality of rails are comprised of a different material than the one or more cushioning layers. The plurality of rails provide a firm or relatively firm edge around the cushioning layers. A size of the cushion member 100 may be based on a size of the cushioning layers (e.g., a first cushioning layer 110, a second cushioning layer 120, and a third cushioning layer 130) and a size of the plurality of rails. In some embodiments, the width of the rails in a lateral direction (i.e., the cushioning member laying on a flat surface with the first cushioning layer 110 on top) is between 1-10 inches. For example, the rail width may be 4 inches. In other embodiments, a different size/dimension is implemented.

[0029]Referring still to FIG. 1, the fire-retardant cap 140 includes a top panel 142, which may correspond to the top of the first cushioning layer 110, coupled to a periphery 148 which may correspond with the sides of the first cushioning layer 110. The periphery 148 extends downwardly from an edge of the top panel 142, surrounding or substantially surrounding an inner surface 146 of the top panel 142. An outer surface 144 of the top panel 142 is substantially parallel to the inner surface 146. The top panel 142 and the periphery 148 may be sewn, ultrasonic welded, glued, fused, and/or otherwise coupled together at or near a boundary between the top panel 142 and periphery 148 to form the fire-retardant cap 140. The fire-retardant cap 140 may be sized such that the fire-retardant cap 140 substantially conforms to the shape of the cushioning layers. For example, as shown in FIG. 1, an inner surface 146 of the fire-retardant cap 140 directly contacts and substantially conforms to the shape of the top of the first cushioning layer 110. The periphery 148 extends downwardly or substantially downwardly along the sides of the first cushioning layer 110, surrounding or mostly surrounding the first cushioning layer 110. In some embodiments, the periphery 148 extends downwardly along the sides of a plurality of cushioning layers, surrounding the plurality of cushioning layers. In some embodiments, the periphery 148 joins at or near a boundary located adjacent to a bottom of a cushioning layer such that the fire-retardant cap 140 encases a cushioning layer or a plurality of cushioning layers. For example, the periphery extends downwardly along the sides of the first cushioning layer 110 and joins/is coupled at a boundary located adjacent to the bottom of the first cushioning layer 110. In such example, the periphery 148 directly contacts and substantially conforms to the bottom of the first cushioning layer 110 such that the fire-retardant cap 140 encases the first cushioning layer 110. In some embodiments, the periphery 148 extends downwardly along the sides of the first cushioning layer and the second cushioning layer 120 and joins/is coupled at a boundary located adjacent to the bottom of the second cushioning layer 120. In such example, the periphery 148 directly contacts and substantially conforms to the bottom of the second cushioning layer 120 such that the fire-retardant cap 140 encases the first cushioning layer 110 and the second cushioning layer 120.

[0030]The fire-retardant cap 140 comprises a fire-retardant or fire-resistant fabric (e.g. scrim, polyester, coated fibers, etc.). A quality of fire-retardant or fire-resistant can be determined by regulatory standards, flammability properties (e.g., ignition temperature, flame spread rate, after flame time, smoke production, heat release rate, toxicity of combustion products, self-extinguishing properties, flash point, etc.) or a combination thereof. Examples include whether a fabric has a peak rate of heat release of 200 kilowatts (kW), whether the total heat release shall not exceed 15 megajoules (MJ), and/or any other standard (e.g., any other standard measuring flammability properties). In some embodiments, the top panel 142 and the periphery 148 comprises different fire-retardant fabric. Additionally, the top panel 142 of the fire-retardant cap 140 may comprise a fire-retardant fabric that bonds with a cushioning element through adhesives, heat, ultrasonic welding, or other chemical or physical bonding application. For example, in FIG. 1, the top panel 142 may comprise a scrim-like material that has a peak rate of heat release less than 200 kW within 30 minutes (min) of exposure to a flame and that fuses with heated gel. In some embodiments, the top panel 142 is thicker than the periphery 148. In some embodiments, the top panel 142 or the periphery 148 comprises a mix of fabrics, coatings, fibers, or other materials with fire-retardant or fire-resistant properties.

[0031]Referring now to FIG. 2, a side view of cushioning layers and a fire-retardant cap 140 assembled into a cushion member 100 is shown, according to an exemplary embodiment. The cushion member 100 includes at least one cushioning layer and a fire-retardant cap 140. As illustrated, the cushion member 100 includes a first cushioning layer 110, a second cushioning layer 120, a third cushioning layer 130, and a fire-retardant cap 140. The first cushioning layer 110 comprises a gel, the second cushioning layer 120 comprises a foam, and the third cushioning layer 130 comprises coils. Each cushioning layer includes a top, a plurality of sides extending vertically or substantially vertically downward from the top, and a bottom positioned on an opposite side relative to the top. In some embodiments, the plurality of cushioning layers and the fire-retardant cap 140 are arranged in a stack. In such embodiments, a cushioning layer may be sewn, ultrasonic welded, glued, fused, or otherwise coupled with an adjacent cushioning layer and the fire-retardant cap 140 may be sewn, ultrasonic welded, glued, fused, or otherwise coupled with a topmost cushioning layer. In the example shown, the bottom of the first cushioning layer 110 directly contacts the top of the second cushioning layer 120 such that the sides of the first cushioning layer 110 are substantially tangential with the sides of the second cushioning layer 120. The bottom of the seconding cushioning layer 120 directly contacts the top of the third cushioning layer 130 such that the sides of the second cushioning layer 120 is substantially tangential with the sides of the third cushioning layer 130. The sides of the cushioning layers are substantially tangential with one another.

[0032]Referring still to FIG. 2, the fire-retardant cap 140 includes a top panel 142, which may correspond to the top of the first cushioning layer 110 coupled to a periphery 148. The periphery 148 may correspond with the sides of the first cushioning layer 110. The periphery 148 extends downwardly from an edge of the top panel 142. The top panel 142 and the periphery 148 may be sewn, ultrasonic welded, glued, fused, and/or otherwise coupled together at a boundary between the top panel 142 and periphery 148 to form the fire-retardant cap 140. In some embodiments, the top panel 142 and the periphery are formed around one or more of a first cushioning layer 110, a second cushioning layer 120, a third cushioning layer 130. The fire-retardant cap 140 is sized such that the fire-retardant cap 140 substantially conforms to the shape of the cushioning layers. As shown in FIG. 2, an inner surface 146 of the fire-retardant cap 140 directly contacts and substantially conforms to the shape of the top of the first cushioning layer 110. The periphery 148 extends downwardly along the sides of the first cushioning layer 110, surrounding the first cushioning layer 110. In some embodiments, the periphery 148 extends downwardly along the sides of a plurality of cushioning layers, surrounding the plurality of cushioning layers.

[0033]Referring still to FIG. 2, the fire-retardant cap 140 comprises a fire-retardant or fire-resistant fabric. A quality of fire-retardant or fire-resistant can be determined by regulatory standards, flammability properties, or a combination thereof. In some embodiments, the top panel 142 of the fire-retardant cap 140 comprises a fire-retardant fabric that bonds with a cushioning element through adhesives, heat, ultrasonic welding, and/or other chemical or physical bonding application. For example, in FIG. 2, the top panel 142 comprises a fire-retardant scrim-like material that has a peak rate of heat release less than 200 kW within 30 minutes (min.) of exposure to a flame and that fuses with heated gel. As illustrated, the inner surface 146 is bonded with the heated gel in the top of the first cushioning layer 110. An outer surface 144 of the top panel 142 is substantially parallel to the inner surface 146 and is oriented outwardly away from the top of the first cushioning layer 110. The outer surface 144 of the top panel 142 acts as a topmost surface of the cushion member 100 that allows the bonding of additional layers of comfort, support, covering, fire barriers, or moisture barriers.

[0034]In some embodiments, the top panel 142 and the periphery 148 each comprise a fire-retardant or fire resistant fabric. In some embodiments, the periphery 148 comprises a scrim fabric (e.g., a woven or non-woven fabric material) that fuses with heated gel. In some embodiments, the top panel 142 and the periphery 148 are installed separately. The periphery 148 may be applied around the bottoms and/or sides of the cushion member 100 and then coupled (e.g., sewn, glued, scrimmed, etc.) to the top panel 142 to encase the cushion member 100.

[0035]Referring now to FIG. 3, a flow diagram of a process 200 of manufacturing a cushion member 100 or a portion thereof is shown, according to an exemplary embodiment. The process 200 may be used as a finishing step in manufacturing a cushion member 100. The process 200 includes step 210 of providing a cushioning layer 110 with a top made of gel or mostly made of gel (e.g., an elastomeric material, etc.). At step 220, a fire-retardant cap 140 with an inner surface 146 made of a fire-retardant or fire-resistant scrim material is provided. The inner surface 146 of the fire-retardant cap 140 directly contacts a top of the cushioning layer 110. At step 230, a contact point at the top of the cushioning layer 110 and the inner surface 146 of the fire-retardant cap 140 are heated to melt or soften the gel and bond the fire-retardant cap 140 to the cushioning layer 110. In some embodiments, the top of the cushioning layer 110 is directly heated, thereby melting or softening the gel. In other embodiments, the inner surface 146 of the fire-retardant cap 140 is directly heated, indirectly melting or softening the gel. In some embodiments, a combination of direct heat to the top of the cushioning layer 110 and the inner surface 146 of the fire-retardant cap 140 is applied. The heating is provided by a heating element or heat source (e.g. oven, water bath, microwave, infrared heater, heat pads, etc.) capable of emitting the energy necessary to facilitate the bonding (e.g., adhesives, melting, ultrasonic welding, or other chemical or physical bonding application) of a cushioning element to the fire-retardant cap 140. In the example shown, the bonding involves melting or softening a gel. In other embodiments, the bonding involves activating a heat-activated adhesive.

[0036]Referring now to FIG. 4, a flow diagram of a process 400 of manufacturing a cushion member 100 or a portion thereof is shown, according to an exemplary embodiment. The process 400 may be used as a finishing step in manufacturing a cushion member 100. The process 400 includes step 410 of providing a cushioning layer 110 with a top made of gel. In some embodiments, the cushioning layer is the first cushioning layer 110. At step 420, a scrim material is added to one side, adjacent a bottom of the cushioning layer. The scrim material may be a fabric material (e.g., a woven and/or non-woven fabric material) that when heated while in contact with the cushioning layer fuses with the heated gel of the cushioning layer to bond the scrim to the cushioning layer. The scrim material is positioned on the cushioning layer such that the scrim material lays flat against the cushioning layer such that there are no wrinkles on the scrim. A size of the scrim material is selected based on a desired size for the overall cushioning member. In some embodiments, in manufacturing the cushion member, a plurality of rails are provided around a perimeter of the cushioning layers (e.g. a first cushioning layer 110, a second cushioning layer 120, and a third cushioning layer 130). In such embodiments, a size of the scrim material is based on a size of the cushioning layers and a size of the plurality of rails. In some embodiments, a size of the scrim material is larger than a total size of the cushioning layers and the plurality of rails by a predefined distance. In some embodiments, the predefined distance is 1-10 inches. For example, the predefined distance may be 2 inches. In such embodiments, the scrim material is extending 2 inches beyond the cushioning layer and the plurality of rails. In other embodiments, a different predefined distance is used.

[0037]Referring to FIG. 5, an example embodiment of step 420 is shown to include positioning the periphery 148 over the cushioning layer 110. The periphery 148 is sized to extend beyond the edges of the cushioning layer 110 to account for both the plurality of rails to be added as well as the predefined distance.

[0038]Referring again to process 400 of FIG. 4, at step 430 the scrim material is coupled to a bottom of the cushioning layer. The scrim material may be coupled to the cushioning layer by being sewn, ultrasonic welded, glued, fused, and/or otherwise coupled to the cushioning layer.

[0039]At step 440, a template based on size of the ultimate cushion member is provided. The size of the ultimate cushion member is based on a size of the cushioning layers (e.g. a first cushioning layer 110, a second cushioning layer 120, and a third cushioning layer 130) and, if present, a size of the plurality of rails extending around the cushioning layers. The template is sized to match the size of the ultimate cushion member, including if present the plurality of rails. In some embodiments, a template from a plurality of templates is selected based on the ultimate size of the cushion member. In some embodiments, the template includes one or more markings indicating a position for the cushioning layer. The template refers to generally flat sheet of material configured to assist with the accurate positioning of the cushioning layers, the plurality of rails, if present, and the fire-retardant cap relative to one other for scrimming. For example, the template provides a guide for where to place the corners of the fire-retardant cap. In some embodiments, the template includes a mark at the boundary line between the cushioning layers and the plurality of rails. For example, if the rails have a width of 4 inches, a mark 4 inches from the border of the may be applied to a top surface of the template. The template may be made of a foam, plastic (e.g., plexiglass, ABS, etc.) wood, or metal (e.g., metal frame). The material of the template is chosen to reduce possible damage to a scrimming machine or the other cushion member components, and to allow the fire-retardant cap to be scrimmed accurately. A template made of a softer material may allow the corners to pull in and collapse the gel of the cushioning layer during scrimming.

[0040]Referring now to FIG. 6, an example embodiment of step 440 is shown. In this example, the template 150 is made of or mostly made of a foam. The material of the template may be relatively stiff so that a top panel 142 of a fire-retardant cap (shown in FIG. 6) can be positioned without collapsing or compressing the cushioning layer. In some embodiments, the template 150 includes an indicator 152. The indicator 152 is a marking or guide showing a proper or desired positioning of the cushioning layer. This may help with assembling to reduce errors in the assembly process. The position of the indicator 152 on the template 150 is based on a size of the cushioning layer and the plurality of rails, if present. The indicator 152 is positioned to indicate the boundary of the cushioning layer and the plurality of rails.

[0041]Referring again to process 400 of FIG. 4, at step 450 the cushioning layer is positioned on the template. In some embodiments, the cushioning layer is positioned on the template according to the one or more markings on the template (i.e., the indicator 152). In some embodiments, the cushioning layer is positioned with the bottom against the template. At step 460, a fire-retardant cap is positioned on the template over the cushioning layer. In some embodiments, the fire retardant cap may be the cap 140. In some embodiments, the fire-retardant cap is the top panel 142. The corners of the fire-retardant cap may be aligned with the corners of the template (e.g., via a machine and/or a human operator). In some embodiments, excess material of the fire-retardant cap is folded or tucked around and underneath the template. In some embodiments, one or more fasteners (e.g., pegs, clamps, etc.) pull the fire-retardant cap down around the cushioning layer.

[0042]Referring now to FIG. 7, the fire-retardant cap 140 is shown positioned above the template 150 and over the cushioning layer 110. The excess material of the fire-retardant cap 140 that extends beyond an edge of the template 150 is folded under the template 150.

[0043]Referring again to process 400 of FIG. 4, at step 470 the fire-retardant cap is coupled to the cushioning layer. In some embodiments, the fire-retardant cap is scrimmed to the cushioning layer. Scrimming involves heating the stack of the fire-retardant cap and the cushioning layer for at a predefined temperature for a predefined time. The predefined time and/or predefined temperature may depend on a thickness of the fire-retardant cap. For example, a first fire-retardant cap of a first thickness may be scrimmed at 360 degrees Fahrenheit for 35 seconds, while a second fire-retardant cap of a second thickness greater than the first thickness may be scrimmed at 460 degrees Fahrenheit for 35 seconds. In this example, the second fire-retardant cap has a second thickness that is greater than the first thickness of the first fire-retardant cap.

[0044]In some embodiments, step 430 is performed after step 470 described below. In other embodiments, step 430 is performed before step 470. Coupling the scrim material to the cushioning layer in step 430 stiffens the cushioning layer and improves the evenness of the scrimming in step 470, therefore preventing the gel of the cushioning layer 110 from being scrimmed unevenly in the later scrimming of the fire-retardant cap 140

[0045]In some embodiments, after step 470 the fire-retardant cap is coupled to the scrim material. The fire-retardant camp may be sewn, ultrasonic welded, glued, and/or otherwise coupled to the scrim material. In such embodiments, the fire-retardant cap and the scrim material encase or substantially encase the cushioning layer.

[0046]As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0047]The term “coupled” as used herein means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0048]References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. References to at least one of a conjunctive list of terms may be construed as an inclusive OR to indicate any of a single, more than one, and all of the described terms. For example, a reference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only ‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunction with “comprising” or other open terminology can include additional items.

[0049]References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0050]The construction and arrangement of the elements of the assembly as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied.

[0051]Additionally, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Rather, use of the word “exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

[0052]Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. For example, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also, for example, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.