High comfort mattresses having fiberballs

Abstract

In one embodiment, a mattress is constructed of a core having a first side and a second side. A padding layer is positioned at the first side of the core and has a contoured surface and a planar surface. A layer of individual fiberballs is disposed on the planar surface of the padding layer.

1 . A mattress comprising:
 a core having a first side and a second side;   a padding layer positioned above at the first side of the core; and   a layer of individual fiberballs disposed on the padding layer; and   a layer of viscoelastic material positioned above the layer of individual fiberballs, wherein the layer of individual fiberballs serve to disperse heat away from a user.   
     
     
         2 . A mattress as in  claim 1 , wherein the fiberballs comprise a plurality of randomly arranged and entangled fibers having a size in the range from about 1 mm to about 20 mm. 
     
     
         3 . A mattress as in  claim 2 , wherein the fibers comprise polyester fibers having a cut length up to about 100 mm and are conjugated or spirally crimped. 
     
     
         4 . A mattress as in  claim 1 , wherein the padding layer comprises a polyurethane foam. 
     
     
         5 . A mattress as in  claim 1 , wherein the layer of fiberballs has a density that is in the range from about 0.5 ounces per square foot to about 3 ounces per square foot. 
     
     
         6 . (canceled) 
     
     
         7 . A mattress as in  claim 1 , further comprising a padding material disposed between the core and the padding layer. 
     
     
         8 . A mattress as in  claim 7 , wherein the padding material is selected from a group of materials consisting of polyurethane foam, latex and visco-elastic materials. 
     
     
         9 . A mattress as in  claim 1 , wherein the padding layer has a thickness in the range from about ⅜ inch to about 3 inches. 
     
     
         10 . A mattress as in  claim 1 , wherein the core is selected from a group consisting of spring cores, latex cores, visco-elastic cores and bladders. 
     
     
         11 . A mattress as in  claim 1 , further comprising a ticking layer disposed over the layer of fiberballs, and a foam material disposed between the ticking layer and the layer of fiberballs. 
     
     
         12 . A mattress comprising:
 a core having a first side and a second side;   a polyurethane padding layer positioned at the first side of the core;   a layer of fiberballs positioned adjacent the padding layer; and   a viscoeleastic layer position above the layer of fiberballs.   
     
     
         13 . (canceled) 
     
     
         14 . A mattress as in  claim 12 , wherein the fiberballs comprise a plurality of randomly arranged and entangled fibers having a size in the range from about 1 mm to about 20 mm. 
     
     
         15 . A mattress as in  claim 14 , wherein the fibers comprise polyester fibers having a cut length up to about 100 mm and are conjugated or spirally crimped. 
     
     
         16 . A mattress as in  claim 14 , wherein the layer of fiberballs has a density that is in the range from about 0.5 ounces per square foot to about 3 ounces per square loot. 
     
     
         17 . A mattress as in  claim 12 , wherein the padding layer is convoluted. 
     
     
         18 . A mattress as in  claim 12 , further comprising a padding material between the core and the padding layer. 
     
     
         19 . A method as in  claim 18 , wherein the padding material is selected from a group of materials consisting of polyurethane foam, latex materials and visco-elastic materials. 
     
     
         20 . A mattress as in  claim 12 , wherein the padding layer has a thickness in the range from about ⅜ inches to about 3 inches. 
     
     
         21 . A mattress as in  claim 12 , wherein the core is selected from a group consisting of spring cores, latex cores, visco-elastic cores and bladders. 
     
     
         22 . A mattress as in  claim 12 . further comprising another padding layer and another fiberball layer positioned at the second side of the core. 
     
     
         23 - 28 . (canceled) 
     
     
         29 . A mattress comprising:
 a core having a first side and a second side;   a padding layer positioned above the first side of the core; and   a layer of a fibrous material disposed above the padding layer; and   a layer of viscoelastic material positioned above the layer of fibrous material, wherein the layer of fibrous material serves to disperse heat away from a user.   
     
     
         30 . A mattress as in  claim 29 , wherein the layer of fibrous material comprises fiberballs.