Three dimensional polylactide fiber matrix layer for bedding products

Abstract

A three dimensional polymeric fiber matrix layer for use in a bedding product such as a mattress is disclosed. The three dimensional polymeric fiber matrix layer generally includes a plurality of randomly oriented polylactide (PLA) fibers bonded at coupling points between adjacent PLA fibers and having a free volume per unit area of the layer.

1 . A three dimensional polymeric fiber matrix layer for a mattress construction, comprising:
 a plurality of randomly oriented polylactide (PLA) fibers bonded at coupling points between adjacent PLA fibers and having a free volume per unit area of the layer, wherein the three dimensional polymeric fiber matrix layer is preconditioned, wherein a portion of the coupling points are detached and a portion of the randomly oriented polymer fibers become fragments so as to change a mechanical property of the pre-conditioned three dimensionally PLA fiber matrix layer relative to the three dimensionally PLA fiber matrix layer without pre-conditioning.   
     
     
         2 . (canceled) 
     
     
         3 . The three dimensional polymeric fiber matrix layer of  claim 1 , wherein the PLA is selected from the group consisting of racemic PLLA (poly-L-lactic Acid), regular PLLA (poly-L- lactic Acid), PDLA (poly-D-lactic Acid), PDLLA (poly-DL-lactic Acid), PLGA (poly-lactic-co- glycolic Acid), PCL (polycaprolactone), and combinations thereof. 
     
     
         4 . The three dimensional polymeric fiber matrix layer of  claim 1 , wherein the change in the mechanical property is a thickness decrease to the preconditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         5 . The three dimensional polymeric fiber matrix layer of  claim 1 , wherein the change in the mechanical property is an indention force deflection decrease to the preconditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         6 . The three dimensional polymeric fiber matrix layer of  claim 1 , wherein the three dimensional PLA fiber matrix layer comprises multiple zones of the polymer fibers having different densities and/or indention force deflection values. 
     
     
         7 . The three dimensional polymeric fiber matrix layer of  claim 1 , wherein the three dimensional PLA fiber matrix layer has a height dimension of 1 to 6 inches. 
     
     
         8 . The three dimensional polymeric fiber matrix layer of  claim 1 , wherein the three dimensional polymeric fiber matrix layer has an indention force deflection ranging from 5 to 25 pounds-force. 
     
     
         9 . A mattress comprising:
 at least one three dimensionally PLA fiber matrix layer comprising randomly oriented PLA fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer, wherein the at least one three dimensionally PLA fiber matrix layer is pre-conditioned such that a portion of the coupling points are detached and a portion of the randomly oriented polymer fibers become fragments so as to change a mechanical property of the pre-conditioned three dimensionally PLA fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre- conditioning.   
     
     
         10 . (canceled) 
     
     
         11 . The mattress of  claim 9 , wherein the at least one three dimensionally PLA fiber matrix layer is intermediate at least one upper foam layer and a lower base layer. 
     
     
         12 . The mattress of  claim 11 , wherein the at least one upper foam layer comprises a viscoelastic foam. 
     
     
         13 . The mattress of  claim 11 , wherein the lower base layer comprises a polyurethane foam or latex foam. 
     
     
         14 . The mattress of  claim 11 , wherein the lower base layer comprises a coil spring innercore disposed within a foam bucket assembly. 
     
     
         15 . The mattress of  claim 11 , wherein the lower base layer and the at least one upper foam layer are formed of the three dimensional PLA fiber matrix layer. 
     
     
         16 . The mattress of  claim 9 , wherein the extruded three dimensional PLA fiber matrix layer comprises multiple zones of the PLA fibers having different densities and/or indention force deflection values. 
     
     
         17 . The mattress of  claim 9 , wherein the three dimensionally PLA fiber matrix layer has a height dimension of 1 to 6 inches. 
     
     
         18 . The mattress of  claim 9 , wherein the three dimensionally PLA fiber matrix layer has an indention force deflection ranging from 5 to 25 pounds-force. 
     
     
         19 . The mattress of  claim 9 , wherein the PLA is selected from the group consisting of racemic PLLA (poly-L-lactic Acid), regular PLLA (poly-L-lactic Acid), PDLA (poly-D-lactic Acid), PDLLA (poly-DL-lactic Acid), PLGA (poly-lactic-co-glycolic Acid), PCL (polycaprolactone), and combinations thereof.