WO2022173771A1

WO2022173771A1 - Mattresses and body-support pads/mats, and methods of manufacture

Info

Publication number: WO2022173771A1
Application number: PCT/US2022/015719
Authority: WO
Inventors: Mark SMIDERLE; Lloyd Wilson; Danielle IGNAZZI; Christine MCKIERNAN; Erik Sanchez; Ben DUCATTEEUW
Original assignee: Soft-Tex International, Inc.
Priority date: 2021-02-09
Filing date: 2022-02-09
Publication date: 2022-08-18

Abstract

Mattresses, body-support pads or mats, and related methods of manufacture are disclosed. The mattress (200) includes an enclosure section (210) sized to extend a width and a length of the mattress, where the length is longer than the width. The enclosure section (210) includes a plurality of feathers and an enclosure (212) including at least one sewn box construction (214) at least partially defined by stitching (216) that encloses multiple feathers of the plurality of feathers. A base section (230) extends the width and length of the mattress (200), and includes a plurality of springs (232). The enclosure section (210) overlies the base section (230). At least the enclosure section (210) is capable of fully degrading within 365 days after customary disposal of the mattress (200).

Description

MATTRESSES AND BODY-SUPPORT PADS/MATS. AND METHODS OF

MANUFACTURE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The application claims priority benefit of U.S. Provisional Patent Application No. 63/147,328, filed on February 9, 2021, and entitled Mattresses and Body-Support Pads/Mats, and Methods of Manufacture, the entire contents of both of which is hereby expressly incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure generally relates to bedding products, and more particularly to body-support cushions, mattresses, and pads or mats that have improved biodegradability, as well as related methods.

BACKGROUND

[0003] It is estimated that approximately 20 million mattresses are discarded every year, equating to roughly 55,000 mattresses that are disposed of each day. It is believed that these mattresses result in 450 million pounds of waste and occupy more than 100 million cubic feet of landfill space each year (see CascadeAlliance, The State of the Mattress Recycling Industry, 3^rd edition, July 2017). Many existing mattresses contain non-biodegradable synthetic foam and fibers, which is why many municipalities and private waste disposal companies typically charge additional disposal fees for disposing of a mattress. Current estimates indicate that it can take as long as 80 to 120 years for innerspring mattresses to decompose and up to 1,000 years for polyurethane-based mattresses (i.e. memory foam mattresses) to fully decompose.

[0004] Often, many individuals select or purchase a mattress based primarily on the mattress’s comfort level. The comfortability of a mattress plays a crucial role in a person’s quality and quantity of sleep, which can affect the person’s overall health. Synthetic foam is often used to provide necessary body support and can easily conform to the shape of the person’s body. However, as noted, synthetic foam is non-biodegradable, and can be harmful to the environment. Thus, a need exists to find more environmentally conscious materials for mattresses and bedding products such as body-support cushions and mats/pad that still provide the desired comfort level in order to provide a person with optimal sleep.

[0005] While certain aspects of conventional technologies have been discussed to facilitate disclosure of the invention, Applicants in no way disclaim these technical aspects, and it is contemplated that the claimed invention may encompass one or more of the conventional technical aspects discussed herein.

[0006] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY

[0007] Shortcomings of the prior art are overcome and additional advantages are provided through improved mattresses, body-support cushions, and pads or mats disclosed herein. In particular, the mattresses, body-support cushions, and body-support pads or mats are believed to provide improved biodegradability over existing sleeping systems. It is also contemplated that the mattresses, body-support cushions, and pads or mats disclosed herein may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the disclosed mattresses, body-support cushions, and pads or mats should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

[0008] Certain embodiments of the presently disclosed mattresses, body-support cushions, and pads or mats have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the mattresses, body-support cushions, and pads or mats as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art.

[0009] In one aspect, disclosed herein is a mattress that provides improved biodegradability, the mattress includes an enclosure section sized to extend a width and a length of the mattress, wherein the length is longer than the width. The enclosure section includes a plurality of feathers and an enclosure that includes at least one sewn box construction that is at least partially defined by stitching that encloses multiple feathers of the plurality of feathers. The mattress further includes a base section extending the width and length of the mattress, where the base section includes a plurality of springs. Further, the enclosure section overlies the base section in a depth direction that extends from a proximal portion of the mattress, which is proximate to a resting surface of the mattress that is capable of supporting one or more users of the mattress, to a distal portion of the mattress that is distal to the resting surface of the mattress. Further, at least the enclosure section is capable of fully degrading within 365 days after customary disposal of the mattress. In some embodiments, the plurality of feathers include chicken feathers.

[0010] In another aspect, the present disclosure provides a body-support pad or mat that provides improved biodegradability, the body-support pad or mat including an enclosure section sized to extend a width and a length of the body-support pad or mat, wherein the length is longer than the width. The enclosure section includes a plurality of feathers and an enclosure that includes at least one sewn box construction that is at least partially defined by stitching that encloses multiple feathers of the plurality of feathers. The body-support pad or mat further includes a base section extending the width and length of the body-support pad or mat, where the base section includes a plurality of springs. Further, the enclosure section overlies the base section in a depth direction that extends from a proximal portion of the body-support pad or mat, which is proximate to a resting surface of the body-support pad or mat that is capable of supporting one or more users of the body-support pad or mat, to a distal portion of the body-support pad or mat that is distal to the resting surface of the body-support pad or mat. Further, at least the enclosure section is capable of fully degrading within 365 days after customary disposal of the body- support pad or mat. In some embodiments, the plurality of feathers include chicken feathers. [0011] In another aspect, the present disclosure provides a method of manufacture that includes producing the mattress or body-support pad or mat disclosed above.

[0012] These and other features and advantages of the disclosure and inventions will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Aspects described herein are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0014] FIG. 1 depicts an elevational perspective view of an exemplary mattress, according to the present disclosure;

[0015] FIG. 2 depicts a cross-sectional view of an exemplary mattress, according to the present disclosure;

[0016] FIG. 3 A depicts an overhead view of an enclosure section of a mattress, according to the present disclosure;

[0017] FIG. 3B depicts an overhead view of a base section of the mattress of FIG. 3 A, according to the present disclosure;

[0018] FIG. 4A depicts an overhead view of an enclosure section of a mattress, according to the present disclosure;

[0019] FIG. 4B depicts an overhead view of a base section of the mattress of FIG. 4A, according to the present disclosure;

[0020] FIG. 5 is a cross-sectional side view of a mattress, according to the present disclosure; and

[0021] FIG. 6 is a cross-sectional side view of a mattress, according to the present disclosure. DETAILED DESCRIPTION

[0022] Aspects of the present disclosure and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the details of the inventions. It should be understood, however, that the detailed description and the specific example(s), while indicating embodiments of inventions of the present disclosure, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

[0023] Approximating language, as used herein throughout disclosure, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” or “substantially,” is not limited to the precise value specified.

[0024] Described herein are mattresses and body-support pads of mats that have improved biodegradability. In one aspect disclosed herein is a mattress that includes an enclosure section sized to extend a width and a length of the mattress, where the length is longer than the width. The enclosure section includes a plurality of feathers and an enclosure that includes at least one sewn box construction that is at least partially defined by stitching, where the stitching encloses multiple feathers of the plurality of feathers. The mattress also includes a base section extending the width and length of the mattress, and the base section includes a plurality of springs. Further, the enclosure section overlies the base section in a depth direction that extends from a proximal portion of the mattress, which is proximate to a resting surface of the mattress that is capable of supporting one or more users of the mattress, to a distal portion of the mattress that is distal to the resting surface of the mattress. Still further, at least the enclosure section is capable of fully degrading within 365 days after customary disposal of the mattress.

[0025] In some embodiments, the plurality of feathers include landfowl feathers (e.g., poultry or chicken feathers) rather than feathers from traditional waterfowl such as ducks, geese, etc. Advantageously, chicken feathers are abundant, easily accessible, and less expensive than feathers from waterfowl. In the U.S., approximately 8 billion chickens are consumed each year, which contributes to an estimated approximately 6 billion tons of chicken feather byproducts produced in the U.S. each year. The quantity of chicken feathers produced each year have created disposal problems, with the feathers often being incinerated, buried, dried and made into livestock feed, or made into biofertilizer. Despite efforts to incorporate chicken feather byproducts into useful processes, it is estimated that a large portion of chicken feather byproducts are wasted.

[0026] Consumers are familiar with down feathers and waterfowl feathers in coats and blankets, but the reason for including waterfowl feathers for those purposes typically are related to their insulating properties to provide warmth. In contrast, consumers typically purchase mattresses and/or body-support pads or mats for the comfort level, firmness, softness, etc. rather than the warming properties of the mattress and/or body-support pads or mats. Thus, chicken feathers are an abundant resource that could be incorporated into mattresses and/or body-support pads or mats.

[0027] Advantageously, unlike polyurethane or other foams typically used in mattresses, chicken feathers safely biodegrade, and often release beneficial nitrogen into the soil. Current estimates indicate that it can take as long as 1,000 years for polyurethane-based mattresses to fully decompose, which is hazardous and harmful to the environment. Thus, a long-felt and unresolved need exists for mattresses and/or body-support pads or mats having improved degradability and potentially biodegradability in order to address environmental concerns posed by polyurethane-based mattresses and/or body-support pads or mats, while still providing a comfortability level sought using polyurethane-based mattresses.

[0028] Another advantage, which is unexpected and an improvement over existing mattresses, is that using chicken feathers in mattresses and/or body-support pads or mats improves resistance to flammability when compared to polyurethane elastic foams. In particular, an unexpected property of using chicken feathers is that chicken feathers are much less flammable than traditional polyurethane elastic foam materials. Polyurethane elastic foams burn readily, so typically mattress manufacturers have to incorporate various additives like anti-pyrenes, including those containing halogens, in order to limit flammability of the polyurethane elastic foams. However, such halogens are very harmful for the environment, and many halogen- containing anti-pyrenes have been banned by the European Union due to the harm caused to the environment. In contrast, chicken feathers act as a flame retardant when compared to polyurethane elastic foams, and can comply with governmental flammability requirements in addition to providing a safer surface upon which to sleep.

[0029] Although some exemplary embodiments of the disclosed mattress of the present disclosure are illustrated and/or described as a mattress for a bed, it is contemplated that the aspects and features described therewith are equally applicable to other forms of furniture including, but not limited to, futon mattresses, couch/chair cushions, and seat cushions, as well as other textile-related applications. Similarly, in another aspect, disclosed herein are body- support pads or mats such as, for example, any and all such objects having a size and shape, and that are otherwise capable of or are generally used to support a body of a person or a portion thereof. Although some exemplary embodiments of the disclosed body-support pads or mats of the present disclosure are illustrated and/or described as mattress pads and/or mattress mats, and thereby may be dimensionally sized to support the entire or the majority of the body of a user (i.e., a person), it is contemplated that the aspects and features described therewith are equally applicable to furniture.

[0030] Referring now to FIG. 1, an elevational perspective view of an exemplary mattress 100 is depicted, according to the present disclosure. The mattress 100 includes an enclosure section (see FIG. 2) and a base section (see FIG. 2), which both may be enclosed by an outer cover 102. The mattress 100 includes a length (LI) and a width (Wl), where the length is longer than the width. The enclosure section (see FIG. 2) may overlie the base section (see FIG. 2) in a depth direction (Dl) that extends from a proximal portion 104 of the mattress 100, where the proximal portion 104 is proximate to a resting surface 106 of the mattress 100, to a distal portion 108 of the mattress 100 that is distal to the resting surface 106 of the mattress 100. Further, the resting surface 106 is capable of supporting one or more users of the mattress 100 and may include the outer cover 102.

[0031] Referring now to FIG. 2, a cross-sectional view of an exemplary mattress 200 is depicted, according to the present disclosure. The mattress 200 includes an enclosure section 210 and a base section 230 that are enclosed by an outer cover 202. The enclosure section 210 is sized to extend a width W1 (W1 of FIG. 1) and a length (LI of FIG. 1) of the mattress 200. Further, the enclosure section 210 may include a plurality of feathers (not shown) that are enclosed by an enclosure 212. For instance, the enclosure 212 may be a bag, sock, pocket, or other include any configuration capable of containing the feathers therein. Further, the enclosure 212 may include at least one sewn box construction 214 that is at least partially defined by stitching 216. For instance, the at least one sewn box construction 214 may be a single box construction that includes an outer border stitching 216 that seals at least a portion of the enclosure 212 to reduce the likelihood that feathers will escape the enclosure 212. In some embodiments, a portion of the enclosure 212 may be sealed using glue, adhesive, or other attachment mechanisms that may be used to contain the feathers therein. The box construction 214 may be of any size or shape based on desired firmness and/or based on a desire to limit migration of the feathers within the enclosure 212. For instance, when a single box construction 214 is used such that the enclosure 212 is essentially one box that extends the entire length and width of the mattress 200, the box may correspond in size to about 2,000 springs of a plurality of springs 232 of the base section 230.

[0032] The at least one sewn box construction 214 may be at least partially defined by stitching 216 that encloses multiple feathers of the plurality of feathers. According to one embodiment, the at least one sewn box construction 214 includes multiple sewn box constructions (e.g. 214A, 214B), where each box construction 214 of the multiple sewn box constructions (e.g. 214A, 214B) is congruent one with another. For instance, in instances with multiple sewn box constructions (e.g. 214A, 214B) each of the box constructions 214 may be the same size and/or shape. In particular, each box construction 214 may be square, rectangular, circular, triangular, polygonal, etc. with a plurality of the box constructions 214 being the same size and/or shape as other box constructions 214. According to one embodiment, the at least one sewn box construction 214 may include a baffle box construction. The stitching 216 may inhibit displacement of the multiple feathers such that the multiple feathers of one sewn box construction (e.g. 214A) cannot traverse to another sewn box construction (e.g. 214B) of the multiple sewn box constructions 214. Standard spring displacement equations may be used to determine displacement of each individual spring. For instance, spring displacement may be 1 _„ calculated based on spring potential energy of PE = -kx , where PE = potential energy, k = the force constant, and x = the distance of displacement from equilibrium. According to one embodiment, the box construction 214 may correspond in size to a range of about 1 spring of the plurality of springs 232 to about 1,000 springs of the plurality of springs 232, or within a range of about 2 springs of the plurality of springs 232 to about 20 springs of the plurality of springs 232, or within a range of about 4 springs of the plurality of springs 232 to about 9 springs of the plurality of springs, or about 6 springs of the plurality of springs.

[0033] According to one embodiment, the plurality of feathers may include landfowl feathers. In particular, the plurality of feathers may include poultry or chicken feathers. According to one embodiment, the plurality of feathers may consist essentially of chicken feathers. According to one embodiment, the plurality of feathers consist of chicken feathers.

[0034] The enclosure section 210 is capable of fully degrading within 365 days after customary disposal of the mattress 200. For instance, after customary disposal of feathers, the plurality of feathers may begin to decompose and degrade within a matter of weeks or at the most approximately 4-6 months. When the feathers are contained in an enclosure 212, the enclosure must begin to degrade within weeks or months as well in order for the feathers to degrade under customary disposal conditions. According to various embodiments, the enclosure 212 may include one or more natural fibers. According to various embodiments, materials for the enclosure 212 may include one or more of cotton, linen, hemp, wool, viscose, rayon, Tencel™, lyocell, micro modal, modal, bamboo, bamboo rayon, cellulose, polylactic acid nylon, Nylong 2- Nylon 6, Amni Soul Eco®, polyamide yarn, polylactic acid fibers, Ingeo™, Ecodear® nylon, Ecodear® PET, and/or viscose, or the like, and/or combinations thereof. Such materials should degrade under customary disposal conditions to an extent that the feathers may begin to decompose and degrade as well such that the entire enclosure section 210 is capable of fully degrading within 365 days after customary disposal of the mattress 200. According to one embodiment, the enclosure section 210 may include one or more additives capable of catalyzing degradation of the enclosure section, where the one or more additives facilitate degradation during conditions of customary mattress disposal. [0035] According to one embodiment, the mattress 200 may include multiple feather density zones, where at least one feather density zone has a higher density of feathers of the plurality of feathers than at least one other feather density zone. The multiple feather density zones may be arranged, according to one embodiment, based on a desired level of body support for a user of the mattress 200. For instance, one feather density zone may have more feathers to provide more structural support and/or firmness to the user than another feather density zone. The feather density zones may be arranged longitudinally and/or latitudinally along the length of the mattress 200

[0036] The base section 230 may extend the full width (W 1 see FIG 1) and length (LI see FIG. 1) of the mattress 200. Further, the base section includes a plurality of springs 232 and the enclosure section 210 may overlie the base section 230 in a depth direction (D1 see FIG. 1). The plurality of springs 232 may have spring gauges that are within a range of about 10 gauge to about 17 gauge. According to various embodiments, the plurality of springs 232 may include hourglass coils such as Bonnell coils and/or offset hourglass coils. According to one embodiment, the plurality of springs 232 may include pocketed coils. The pocketed coils may include individually wrapped or pockets wrapping each individual coils. The pocket may include materials such as one or more natural fibers and/or cotton, linen, hemp, wool, viscose, rayon, Tencel™, lyocell, micro modal, modal, bamboo, bamboo rayon, cellulose, polylactic acid nylon, Nylon 2-Nylon 6, Amni Soul Eco®, polyamide yarn, polylactic acid fibers, Ingeo™, Ecodear® nylon, Ecodear® PET, and/or viscose, or the like, and/or combinations thereof. According to one embodiment, the pockets of the pocketed coils may be capable of fully degrading within 365 days after customary disposal of the mattress 200. According to one embodiment, the plurality of springs 232 may include continuous coils. According to one embodiment, the plurality of springs may include a wire diameter that is within a range of about 1.0 mm to about 2.0 mm. According to various embodiments, at least some of the springs of the plurality of springs 232 may have a different tension than other springs of the plurality of springs 232. According to one embodiment, peripheral springs of the plurality of springs 232 that are positioned or otherwise located around an outer periphery of the mattress 232 may have a thicker gauge than springs internal to the peripheral springs. For instance, the springs positioned around the periphery of the mattress may be sized and shaped or otherwise configured to provide less displacement or depress to a lesser extent than springs that are internal to the peripheral springs. Thus, the peripheral springs on the periphery may provide more stability to a user and may be more firm than the springs internal to the peripheral springs.

[0037] According to one embodiment, the base section 230 may be capable of fully degrading within 365 days after customary disposal of the mattress 200. For instance, although some embodiments of the mattress 200 may include steel springs customarily included in spring mattresses, other embodiments may include a plurality of springs 232 that include biodegradable metal, bioplastic, biodegradable plastic, natural rubber, photodegradable plastic, oxidatively degradable plastic, hydrolytically degradable plastic, degradable plastic, compostable plastic, plastic treated with prodegradent concentrates, polycaprolactone polyester, polyhydroxyalkanoate polyester, polylactic acid, starch-blended plastic, and/or steel, or the like, and/or combinations thereof. According to one embodiment, the base section 230 may include one or more additives capable of catalyzing degradation of the base section 230, where the one or more additives facilitate degradation during conditions of customary mattress disposal.

[0038] Referring now to FIG. 3 A, an overhead view of an enclosure section 310 is depicted, according to the present disclosure. The enclosure section 310 includes an enclosure 312 that encloses a plurality of feathers (not shown). The enclosure 312 includes multiple sewn box constructions 314 that would each include multiple feathers of the plurality of feathers (not shown). According to one embodiment, the enclosure 312 may include one or more featherless sections 320 that are void of any feathers of the plurality of feathers. The featherless sections 320 may be positioned or otherwise located, for example, near the edges and/or periphery of the enclosure 312. For instance, the featherless sections 320 may be located at the ends 318 of the enclosure 312. Featherless section 320 may be located in various other locations of the enclosure 312 based on budgetary constraints, desired comfort, etc.

[0039] Also shown are multiple feather zones 322, 324, 326, 328. According to various embodiments, the enclosure 312 may include a uniform density of feathers across the entirety of the enclosure 312. Other embodiments may include multiple feather density zones (e.g. 322, 324, 326, 328) where each feather density zone includes a different density of feathers. For example, fewer feathers may be included in feather density zones 322 and/or 328 than feather density zones 324 and/or 326. Alternatively, feather density zones 322 and/or 328 may include more feathers than feather density zones 324 and/or 326. According to one embodiment, one feather density zone may include more feathers than any other density zone. For instance, feather density zone 326 may include more feathers than feather density zones 324, 322, and 328. Various other feather density zone configurations are also contemplated herein.

[0040] Referring now to FIG. 3B, an overhead view of a base section 330 is depicted, according to the present disclosure. The base section 330 includes a plurality of springs 332 and may underlie enclosure section 310. According to one embodiment, the base section 330 may include peripheral springs 334, which are located around/about the periphery 338 of the base section 330. The peripheral springs 334 may have a thicker gauge than internal springs 336 internal to the peripheral springs 334. In addition, the lateral displacement of each spring of the plurality of springs 332 may be partially controlled by the gauge of the springs such that the peripheral springs 334 may be more resistant to lateral displacement than the internal springs 336. Lateral displacement may be calculated using the following equation: F_L = + v² — mueo5b)5, where F_L= lateral force, p = density of the object applying the lateral force, m = velocity of the force applied to the mattress, u = velocity of the mattress, b = the angle of the force, and S = cross-sectional contact area of the mattress. The amount of lateral displacement may be within an acceptable range as would be known to a person having ordinary skill in the art, such that the plurality of springs 334 provide sufficient stability to prevent substantial lateral displacement.

[0041] Referring now to FIGS. 4A and 4B, an overhead view of an enclosure section 410 is depicted, according to the present disclosure. The enclosure section 410 includes an example enclosure 412 that includes multiple sewn box constructions 414 that correspond in size to a single spring of the plurality of springs 432 of base section 430 of FIG. 4B. The size of the sewn box construction 414 may vary depending on the desired firmness of the mattress and the desired displacement of the feathers. For instance, an enclosure 412 that includes more sewn box constructions 414 may have less feather displacement because the sewn box constructions 414 inhibit displacement of the feathers from one sewn box construction to another. Additionally, according to various embodiments, the springs of the plurality of springs 432 may have less displacement when used with enclosures 412 with more sewn box constructions 414 than enclosures with less sewn box constructions 414. [0042] Referring now to FIG. 5 a cross-sectional side view of a mattress 500 is depicted, according to the present disclosure. The mattress 500 includes an outer cover 502 that encloses the enclosure section 510 and the base section 530. According to one embodiment, the mattress 500 may include a fire resistant material 504, which may be incorporated into a fire resistant cap or fire resistant sock, positioned between the outer cover 502 and the enclosure 512 of the enclosure section 510. The enclosure 512 may enclose a plurality of feathers 540. The plurality of feathers 540 may be partitioned by one or more sewn box constructions 514.

[0043] Referring now to FIG. 6, a cross-sectional side view of a mattress 600 is depicted, according to the present disclosure. The mattress 600 includes an outer cover 602 that encloses the enclosure section 610 and the base section 630. According to one embodiment, the enclosure 612 of the enclosure section includes, e.g. incorporated therein, fire resistant material. For example, the fire resistant material of the enclosure 612 may be located at a proximal portion 650 of the enclosure section 610 (i.e. the portion of the enclosure 612 closest to where the user rests). In particular, the proximal portion 650 of the enclosure section 610 is located proximate to the resting surface of the mattress 600. The enclosure 612 may enclose a plurality of feathers 640 and the plurality of feathers 640 may be partitioned by one or more sewn box constructions 614.

[0044] According to various embodiments, other layers of material may also be incorporated into the mattress 600. Although not shown, a layer of material may be positioned between the enclosure section 610 and the base section 630. This layer of material may facilitate, for instance, protecting the enclosure section 610 from any protrusions from the plurality of springs of the base section 630. According to one embodiment, the enclosure section 610 may be further protected from protrusion by enclosing each individual spring in a pocket or fabric encasement.

[0045] Also disclosed herein is a body-support pad or mat that includes an enclosure section sized to extend a width and a length of the body-support pad or mat, wherein the length is longer than the width. Further, the enclosure section includes a plurality of feathers and an enclosure that includes at least one sewn box construction that is at least partially defined by stitching that encloses multiple feathers of the plurality of feathers. The body-support pad or mat further includes a base section extending the width and length of the body-support pad or mat, where the base section includes a plurality of springs. Further, the enclosure section overlies the base section in a depth direction that extends from a proximal portion of the body-support pad or mat, which is proximate to a resting surface of the body-support pad or mat that is capable of supporting one or more users of the body-support pad or mat, to a distal portion of the body- support pad or mat that is distal to the resting surface of the body-support pad or mat. Still further, at least the enclosure section is capable of fully degrading within 365 days after customary disposal of the body-support pad or mat. The body-support pad or mat may include and/or be similar to the mattresses described above with respect to FIGS. 1-6, and the description contained herein directed thereto equally applies to the body-support pad or mat but may not be repeated herein below for brevity sake.

[0046] Also disclosed herein is a method of manufacturing the mattress and/or body-support pad or mat described above. The method includes producing a mattress or body-support pad or mat incorporating any and/or all of the aspects described herein. For instance, the method may include packing, blowing, or otherwise inserting feathers into the enclosure sections described above. The method may also include stitching or otherwise sealing the enclosure of the enclosure section such that the feathers are contained therein. The method may also include aligning a plurality of springs of a base section. The method may also include positioning the enclosure section such that it overlies the base section. The method may further include encasing the enclosure section and the base section with an outer covering. Various other method elements are also contemplated herein.

[0047] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”),

“contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

[0048] As used herein, the terms “comprising,” "has," “including,” "containing," and other grammatical variants thereof encompass the terms “consisting of’ and “consisting essentially of.”

[0049] The phrase “consisting essentially of’ or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods.

[0050] All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

[0051] Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

[0052] Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

[0053] While several aspects and embodiments of the present invention have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1. A mattress, comprising: an enclosure section sized to extend a width and a length of the mattress, wherein the length is longer than the width, the enclosure section comprising: a plurality of feathers; an enclosure comprising at least one sewn box construction that is at least partially defined by stitching that encloses multiple feathers of the plurality of feathers; and a base section extending the width and length of the mattress, the base section comprising a plurality of springs; wherein the enclosure section overlies the base section in a depth direction that extends from a proximal portion of the mattress, which is proximate to a resting surface of the mattress that is capable of supporting one or more users of the mattress, to a distal portion of the mattress that is distal to the resting surface of the mattress; wherein at least the enclosure section is capable of fully degrading within 365 days after customary disposal of the mattress.

2. The mattress according to claim 1, wherein the plurality of feathers comprise chicken feathers.

3. The mattress according to any one of the preceding claims, wherein the plurality of feathers are consisting essentially of chicken feathers.

4. The mattress according to any one of the preceding claims, wherein the plurality of feathers consist of chicken feathers.

5. The mattress according to any one of the preceding claims, wherein the mattress further comprises: an outer cover configured to enclose both the enclosure section and the base section.

6. The mattress according to claim 5, wherein the resting surface comprises the outer cover.

7. The mattress according to any one of the preceding claims, wherein the mattress further comprises a fire resistant material.

8. The mattress according to claim 7, wherein the enclosure comprises the fire resistant material.

9. The mattress according to claim 8, wherein the fire resistant material of the enclosure is located at a proximal portion of the enclosure section, the proximal portion of the enclosure section being located proximate to the resting surface of the mattress.

10. The mattress according to any one of the preceding claims, wherein the at least one sewn box construction is a single box construction comprises an outer border stitching sealing at least a portion of the enclosure.

11. The mattress according to claim 10, wherein the single box construction corresponds in size to about 2,000 springs of the plurality of springs.

12. The mattress according to any one of the preceding claims, wherein the at least one sewn box construction comprises multiple sewn box constructions, each box construction of the multiple sewn box constructions being congruent one with another.

13. The mattress according to claim 12, wherein the stitching inhibits displacement of the multiple feathers such that the multiple feathers of one sewn box construction of the multiple sewn box constructions cannot traverse to another sewn box construction of the multiple sewn box constructions.

14. The mattress according to claim 12 or 13, wherein each box construction of the multiple box constructions corresponds in size to a range of about 1 spring of the plurality of springs to about 1,000 springs of the plurality of springs.

15. The mattress according to any one of claims 12-14, wherein each box construction of the multiple box constructions corresponds in size to a range of about 2 springs of the plurality of springs to about 20 springs of the plurality of springs.

16. The mattress according to any one of claims 12-15, wherein each box construction of the multiple box constructions corresponds in size to a range of about 4 springs of the plurality of springs to about 9 springs of the plurality of springs.

17. The mattress according to any one of claims 12-16, wherein each box construction of the multiple box constructions corresponds in size to about 6 springs of the plurality of springs.

18. The mattress according to any one of the preceding claims, wherein the at least one sewn box construction comprises a baffle box.

19. The mattress according to any one of the preceding claims, wherein a total amount of springs of the plurality of springs of the mattress are within a range of about 200 to about 3,000 springs.

20. The mattress according to any one of the preceding claims, wherein gauges of the plurality of springs are within a range of about 10 gauge to about 17 gauge springs.

21. The mattress according to any one of the preceding claims, wherein the plurality of springs comprise hourglass coils.

22. The mattress according to claim 21, wherein the hourglass coils comprise Bonnell coils.

23. The mattress according to claim 21, wherein the hourglass coils comprise offset hourglass coils.

24. The mattress according to any one of the preceding claims, wherein the plurality of springs comprise pocketed coils.

25. The mattress according to any one of the preceding claims, wherein the plurality of springs comprise continuous coils.

26. The mattress according to any one of the preceding claims, wherein the plurality of springs comprise a wire diameter within a range of about 1.0 mm to about 2.0 mm.

27. The mattress according to any one of the preceding claims, wherein at least some of the springs of the plurality of springs have a different tension than other springs of the plurality of springs.

28. The mattress according to any one of the preceding claims, wherein peripheral springs around a periphery of the mattress have a thicker gauge than springs internal to the peripheral springs.

29. The mattress according to any one of the preceding claims, wherein the enclosure comprises one or more of: cotton, linen, hemp, wool, viscose, rayon, Tencel™, lyocell, micro modal, modal, bamboo, bamboo rayon, cellulose, polylactic acid nylon, Nylon 2-Nylon 6, Amni Soul Eco®, polyamide yarn, polylactic acid fibers, Ingeo™, Ecodear® nylon, Ecodear® PET, and/or viscose, and/or combinations thereof.

30. The mattress according to any one of the preceding claims, wherein the enclosure comprises one or more natural fibers.

31. The mattress according to any one of the preceding claims wherein the mattress comprises multiple feather density zones, with at least one feather density zone having a higher density of feathers of the plurality of feathers than at least one other feather density zone.

32. The mattress according to claim 31, wherein the multiple feather density zones are arranged based on desired body support for a user of the one or more users.

33. The mattress according to any one of the preceding claims, wherein the base section is capable of fully degrading within 365 days after customary disposal of the mattress.

34. The mattress according to any one of the preceding claims, wherein the plurality of springs comprise one or more of: biodegradable metal, bioplastic, biodegradable plastic, natural rubber, photodegradable plastic, oxidatively degradable plastic, hydrolytically degradable plastic, degradable plastic, compostable plastic, plastic treated with prodegradent concentrates, polycaprolactone polyester, polyhydroxyalkanoate polyester, polylactic acid, starch-blended plastic, and/or steel, and/or combinations thereof.

35. The mattress according to any one of the preceding claims, wherein the enclosure section comprises one or more additives capable of catalyzing degradation of the enclosure section, the one or more additives facilitating degradation during conditions of customary mattress disposal.

36. The mattress according to any one of the preceding claims, wherein the base section comprises one or more additives capable of catalyzing degradation of the base section, the one or more additives facilitating degradation during conditions of customary mattress disposal.

37. A body-support pad or mat, comprising: an enclosure section sized to extend a width and a length of the body-support pad or mat, wherein the length is longer than the width, the enclosure section comprising: a plurality of feathers; an enclosure comprising at least one sewn box construction that is at least partially defined by stitching that encloses multiple feathers of the plurality of feathers; and a base section extending the width and length of the body-support pad or mat, the base section comprising a plurality of springs; wherein the enclosure section overlies the base section in a depth direction that extends from a proximal portion of the body-support pad or mat, which is proximate to a resting surface of the body-support pad or mat that is capable of supporting one or more users of the body- support pad or mat, to a distal portion of the body-support pad or mat that is distal to the resting surface of the body-support pad or mat; wherein at least the enclosure section is capable of fully degrading within 365 days after customary disposal of the body-support pad or mat.

38. The body-support pad or mat of claim 1, wherein the plurality of feathers comprise chicken feathers.

39. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of feathers are consisting essentially of chicken feathers.

40. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of feathers consist of chicken feathers.

41. The body-support pad or mat according to any one of the preceding claims, wherein the body-support pad or mat further comprises: an outer cover configured to enclose both the enclosure section and the base section.

42. The body-support pad or mat according to claim 5, wherein the resting surface comprises the outer cover.

43. The body-support pad or mat according to any one of the preceding claims, wherein the body-support pad or mat further comprises a fire resistant material.

44. The body-support pad or mat according to claim 7, wherein the enclosure comprises the fire resistant material.

45. The body-support pad or mat according to claim 8, wherein the fire resistant material of the enclosure is located at a proximal portion of the enclosure section, the proximal portion of the enclosure section being located proximate to the resting surface of the body- support pad or mat.

46. The body-support pad or mat according to any one of the preceding claims, wherein the at least one sewn box construction is a single box construction comprises an outer border sealing the enclosure.

47. The body-support pad or mat according to claim 10, wherein the single box construction corresponds in size to about 2,000 springs of the plurality of springs.

48. The body-support pad or mat according to any one of the preceding claims, wherein the at least one sewn box construction comprises multiple sewn box constructions, each box construction of the multiple sewn box constructions being congruent one with another.

49. The body-support pad or mat according to claim 12, wherein the stitching inhibits displacement of the multiple feathers such that the multiple feathers of one sewn box construction of the multiple sewn box constructions cannot traverse to another sewn box construction of the multiple sewn box constructions.

50. The body-support pad or mat according to claim 12 or 13, wherein each box construction of the multiple box constructions corresponds in size to a range of about 1 spring of the plurality of springs to about 1,000 springs of the plurality of springs.

51. The body-support pad or mat according to any one of claims 12-14, wherein each box construction of the multiple box constructions corresponds in size to a range of about 2 springs of the plurality of springs to about 20 springs of the plurality of springs.

52. The body-support pad or mat according to any one of claims 12-15, wherein each box construction of the multiple box constructions corresponds in size to a range of about 4 springs of the plurality of springs to about 9 springs of the plurality of springs.

53. The body-support pad or mat according to any one of claims 12-16, wherein each box construction of the multiple box constructions corresponds in size to about 6 springs of the plurality of springs.

54. The body-support pad or mat according to any one of the preceding claims, wherein the at least one sewn box construction comprises a baffle box.

55. The body-support pad or mat according to any one of the preceding claims, wherein a total amount of springs of the plurality of springs of the body-support pad or mat are within a range of about 200 to about 3,000 springs.

56. The body-support pad or mat according to any one of the preceding claims, wherein gauges of the plurality of springs are within a range of about 10 gauge to about 17 gauge springs.

57. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of springs comprise hourglass coils.

58. The body-support pad or mat according to claim 21, wherein the hourglass coils comprise Bonnell coils.

59. The body-support pad or mat according to claim 21, wherein the hourglass coils comprise offset hourglass coils.

60. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of springs comprise pocketed coils.

61. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of springs comprise continuous coils.

62. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of springs comprise a wire diameter within a range of about 1.0 mm to about 2.0 mm.

63. The body-support pad or mat according to any one of the preceding claims, wherein at least some of the springs of the plurality of springs have a different tension than other springs of the plurality of springs.

64. The body-support pad or mat according to any one of the preceding claims, wherein peripheral springs around a periphery of the body-support pad or mat have a thicker gauge than springs internal to the peripheral springs.

65. The body-support pad or mat according to any one of the preceding claims, wherein the enclosure comprises one or more of: cotton, linen, hemp, wool, viscose, rayon, Tencel™, lyocell, micro modal, modal, bamboo, bamboo rayon, cellulose, polylactic acid nylon, Nylon 2-Nylon 6, Amni Soul Eco®, polyamide yarn, polylactic acid fibers, Ingeo™, Ecodear® nylon, Ecodear® PET, and/or viscose, and/or combinations thereof.

66. The body-support pad or mat according to any one of the preceding claims, wherein the enclosure comprises one or more natural fibers.

67. The body-support pad or mat according to any one of the preceding claims wherein the body-support pad or mat comprises multiple feather density zones, with at least one feather density zone having a higher density of feathers of the plurality of feathers than at least one other feather density zone.

68. The body-support pad or mat according to claim 31, wherein the multiple feather density zones are arranged based on desired body support for a user of the one or more users.

69. The body-support pad or mat according to any one of the preceding claims, wherein the base section is capable of fully degrading within 365 days after customary disposal of the body-support pad or mat.

70. The body-support pad or mat according to any one of the preceding claims, wherein the plurality of springs comprise one or more of: biodegradable metal, bioplastic, biodegradable plastic, natural rubber, photodegradable plastic, oxidatively degradable plastic, hydrolytically degradable plastic, degradable plastic, compostable plastic, plastic treated with prodegradent concentrates, polycaprolactone polyester, polyhydroxyalkanoate polyester, polylactic acid, starch-blended plastic, and/or steel, and/or combinations thereof.

71. The body-support pad or mat according to any one of the preceding claims, wherein the enclosure section comprises one or more additives capable of catalyzing degradation of the enclosure section, the one or more additives facilitating degradation during conditions of customary body-support pad or mat disposal.

72. The body-support pad or mat according to any one of the preceding claims, wherein the base section comprises one or more additives capable of catalyzing degradation of the base section, the one or more additives facilitating degradation during conditions of customary body-support pad or mat disposal.

73. A method of manufacture, comprising: producing a mattress or body-support pad or mat of any one of claims 1-72.