Pre-conditioned three dimensional polymeric fiber matrix layer for bedding products

Abstract

A pre-conditioned three dimensionally polymeric fiber matrix layer for use in a bedding product such as a mattress is disclosed. The pre-conditioned three dimensionally polymeric fiber matrix layer generally includes an extruded three dimensional polymeric fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer, wherein a portion of the coupling points and the randomly oriented polymer fibers are broken so as to change a mechanical property of the pre-conditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning.

1 . A pre-conditioned three dimensionally polymeric fiber matrix layer for a mattress construction, comprising:
 an extruded three dimensional polymeric fiber layer having constant length, width and height dimensions, the extruded three dimensional polymeric fiber layer comprising randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer, wherein a portion of the coupling points are detached and the randomly oriented polymer fibers are broken to become fragments so as to change a mechanical property of the pre-conditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning.   
     
     
         2 . The pre-conditioned three dimensionally 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 the pre-conditioning. 
     
     
         3 . The pre-conditioned three dimensionally 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 the pre-conditioning. 
     
     
         4 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the extruded three dimensional polymer fiber layer is selected from the group consisting of polyesters, polyethylene, polypropylene, nylon, elastomers, copolymers and its derivatives, including monofilament or bicomponent filaments having different melting points. 
     
     
         5 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the extruded three dimensional polymer fiber layer comprises multiple zones of the polymer fibers having different densities and/or indention force deflection values. 
     
     
         6 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has a height dimension of 0.5 to 5.9 inches. 
     
     
         7 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has a height dimension that decreases relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         8 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has a density that increases relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         9 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has an indention force deflection ranging from 4 to 24.9 pounds-force. 
     
     
         10 . The pre-conditioned three dimensionally polymeric fiber matrix layer of  claim 1 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has an indention force deflection that decreases relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         11 . A mattress comprising:
 at least one pre-conditioned three dimensionally polymeric fiber matrix layer comprising a three dimensional polymeric fiber layer having constant length, width and height dimensions, the extruded three dimensional polymeric fiber layer comprising randomly oriented polymer fibers bonded at coupling points between adjacent fibers and having a free volume per unit area of the layer, wherein a portion of the coupling points are detached and the randomly oriented polymer fibers are broken to become fragments so as to change a mechanical property of the pre-conditioned three dimensionally polymeric fiber matrix layer relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning.   
     
     
         12 . The mattress of  claim 11 , wherein the at least one pre-conditioned three dimensionally polymeric fiber matrix layer is intermediate at least one upper foam layer and a lower base layer. 
     
     
         13 . The mattress of  claim 12 , wherein the at least one upper foam layer comprises a viscoelastic foam. 
     
     
         14 . The mattress of  claim 12 , wherein the lower base layer comprises a polyurethane foam or latex foam. 
     
     
         15 . The mattress of  claim 12 , wherein the lower base layer comprises a coil spring innercore disposed within a foam bucket assembly. 
     
     
         16 . The mattress of  claim 11 , wherein the preconditioned three dimensional polymeric fiber layer is selected from the group consisting of polyesters, polyethylene, polypropylene, nylon, elastomers, copolymers and its derivatives, including monofilament or bicomponent filaments having different melting points. 
     
     
         17 . The mattress of  claim 11 , wherein the extruded three dimensional polymeric fiber layer comprises multiple zones of the polymer fibers having different densities and/or indention force deflection values. 
     
     
         18 . The mattress of  claim 11 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has a height dimension of 0.5 to 5.9 inches. 
     
     
         19 . The mattress of  claim 11 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has a height dimension that decreases relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         20 . The mattress of  claim 11 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has a density that increases relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         21 . The mattress of  claim 11 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has an indention force deflection ranging from 4 to 24.9 pounds-force. 
     
     
         22 . The mattress of  claim 11 , wherein the pre-conditioned three dimensionally polymeric fiber matrix layer has an indention force deflection that decreases relative to the three dimensionally polymeric fiber matrix layer without pre-conditioning. 
     
     
         23 . The mattress of  claim 11 , wherein the base layer comprises a polyurethane foam, a latex foam; a polystyrene foam, polyethylene foam, a polypropylene foam, or a polyether-polyurethane foam.