Multi-layered convoluted foam layer
AssigneeDreamwell, Ltd.
InventorChristopher F. Chunglo
Life of this patent
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Abstract
Convoluted foam layers for mattresses, cushions and the like include at least one convoluted surface including at least one convolution that is structurally heterogeneous. The convoluted foam layer is formed of at least two foam layers fixedly attached to one another, wherein the foam layers are of different materials and/or have different properties. Also disclosed are processes for forming the convoluted foam layer and convoluted foam layers having multiple zones of a convoluted surface pattern that includes at least one convolution that is structurally heterogeneous.
Claims21
A convoluted foam layer comprising:
- a multi-layer foam laminate comprising a first layer and at least one additional layer fixedly attached to the first layer;
- wherein the multi-layer foam laminate comprises a convoluted foam surface comprising a plurality of convolutions, wherein at least one of the convolutions has a depth extending from a peak to a valley into the first layer and the at least one additional layer.
A mattress comprising:
- at least one convoluted foam layer having a convoluted surface comprising a plurality of convolutions, wherein at least one of the convolutions is structurally heterogeneous.
A process for manufacturing convoluted foam comprising:
- fixedly attaching at least two foam layers to each other to define a foam laminate, wherein the at least two foam layers are of different materials and/or have different properties;
- and
- forming a convoluted surface in at least one surface of the foam laminate, wherein the convoluted surface comprising a plurality of convolutions formed of the at least two foam layers.
A mattress comprising:
- at least one convoluted foam layer comprising a plurality of zones defined by a convoluted surface pattern, wherein the convoluted surface pattern comprises at least one convolution that is structurally heterogeneous.
Dependencies are inferred from the claim text.