Upcycled mattress nucleus of essential foam elements
AssigneeDenver Mattress Co., LLC
InventorBob Rensink
Life of this patent
Estimating the term…
Abstract
A foam core mattress including a cushion layer having a foam with an IFD of between about 6 to about 18 and a density of between about 1.5 lb./ft3 to about 4 lb./ft3. The mattress includes a core that is coupled with a bottom surface of the cushion layer. The core includes a matrix of rebond foam pieces that includes at least 5% foam pieces having volumes of less than about 0.5 in3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in3, and at least 20% foam pieces having volumes of greater than 2.0 in3, wherein the core has an IFD of between about 21 and 36. The mattress includes a base layer coupled with a bottom surface of the core. The base layer has an IFD of between about 28 to about 70 and a density of between 1.5 lb./ft3 to about 2 lb./ft3.
Claims20
A method of manufacturing a foam core mattress, comprising:
- applying a binder to a plurality of rebond foam pieces to form a mixture;
- compressing the mixture within a mold to form a loaf having an IFD of between about 21 and 36 and a density of between about 3 and 4 pcf;
- applying heat to the loaf to cure the binder;
- cutting the loaf to form a mattress core;
- coupling a base layer to a bottom surface of the mattress core, the base layer having an IFD of between about 24 to about 45 and a density of between 1.5 pcf to about 2 pcf;
- and
- coupling a cushion layer with a top surface of the mattress core, the cushion layer comprising a foam having an IFD of between about 6 to about 18 and a density of between about 1.5 pcf to about 4 pcf.
A method of manufacturing a foam core mattress, comprising:
- forming a mattress core by:
- combining a plurality of rebond foam pieces with a binder to form a mixture, wherein the plurality of rebond foam pieces includes at least 5% foam pieces having volumes of less than about 0.5 in3, at least 40% foam pieces having volumes of between about 0.5 and 2.0 in3, and at least 20% foam pieces having volumes of greater than 2.0 in3;
- compressing the mixture within a mold to form a loaf having an IFD of between about 21 and 36 and a density of between about 3 and 4 pcf;
- applying heat to the loaf to cure the binder;
- coupling a base layer to a bottom surface of the mattress core, the base layer having an IFD of between about 24 to about 45 and a density of between 1.5 pcf to about 2 pcf;
- and
- coupling a cushion layer with a top surface of the mattress core, the cushion layer comprising a foam having an IFD of between about 6 to about 18 and a density of between about 1.5 pcf to about 4 pcf.
A method of manufacturing a foam core mattress, comprising:
- forming a mattress core by:
- combining a plurality of rebond foam pieces with a binder to form a mixture, wherein the plurality of rebond foam pieces comprises at least 35% foam pieces having densities between about 1.5 and 2.2 pcf, at least 40% foam pieces having densities between about 2.2 and 3.0 pcf, and at least 2% foam pieces having densities of less than about 1.5 pcf;
- compressing the mixture within a mold to form a loaf having an IFD of between about 21 and 36 and a density of between about 3 and 4 pcf;
- applying heat to the loaf to cure the binder;
- coupling a base layer to a bottom surface of the mattress core, the base layer having an IFD of between about 24 to about 45 and a density of between 1.5 pcf to about 2 pcf;
- and
- coupling a cushion layer with a top surface of the mattress core, the cushion layer comprising a foam having an IFD of between about 6 to about 18 and a density of between about 1.5 pcf to about 4 pcf.
Dependencies are inferred from the claim text.