Method of manufacturing multi-hardness and multi-elasticity foam mattress by use of continuous foaming process and foam mattress manufactured thereby

A method of manufacturing a multi-hardness and multi-elasticity foam mattress in which a plurality of unit foam blocks are formed integrally with each other by use of a continuous foaming process, the method comprising the steps of:

• arranging a plurality of nozzles (20) at one end of a molding plate (10);
• installing a separation wall (30) between two adjacent ones of the respective nozzles (20) arranged on the molding plate (10);
• laminating a release paper (40) on the top of the molding plate (10);
• spraying foaming solution (50) out of the nozzles (10), wherein the release paper (40) moves towards the other end of the molding plate (10) corresponding to a moving speed of the foaming solution (50);
• and
• molding a foam so as to integrally form a plurality of zones where a plurality of unit foam blocks (60) have a variety of hardnesses and elasticities,
• wherein the foam mattress (100) consists of the plurality of unit foam blocks (60) arranged along a longitudinal direction of the foam mattress;
• wherein at least one pair of the unit foam blocks with a same hardness and elasticity are symmetrical to each other about a central region located between a head region for supporting an upper body of a mattress user and a foot region for supporting a lower body of the user;
• and,
• wherein a number of the plurality of unit foam blocks (60) varies from five to nine.