Foam mat and method for manufacturing a foam mat
AssigneeAladdin Manufacturing Corporation
InventorChunming LIU
Life of this patent
Estimating the term…
Abstract
Foam edge waste may be shredded or ground into foam particles rather than discarding them. The particles may be mixed with an adhesive and subject to high temperature and high pressure to form into new foam bodies with configurable densities. Utilizing discarded foam sections this way reduces the waste of foam, reduces environmental pollution caused by foam waste combustion, offers more environmental protection and saves resources. The resulting foam articles have reduced water retention and provide superior comfort by making a foam with consistent properties from inconsistent materials.
Claims21
1-20. (canceled)
A mat comprising:
- a cushion layer comprising a thickness, a top side, a bottom side, and wherein the top side is bonded to a fabric layer;
- wherein the cushion layer comprises a foam sheet having a foam sheet density;
- and
- wherein the foam sheet is comprised of a plurality of foam particles, wherein each of the foam particles has a first range of sizes and a first range of densities.
A mat comprising:
- a cushion layer comprising a thickness, a top side, a bottom side, and wherein the top side is bonded to a fabric layer;
- wherein the cushion layer has a cushion layer density and comprises a plurality of foam particles bonded together;
- wherein the plurality of foam particles has an average particle density;
- and
- wherein the cushion layer density is greater than the average density.
A method of forming a mat comprising:
- providing a mold;
- determining a desired volume of a cushion within the mold;
- providing a plurality of foam particles, wherein the foam particles in the plurality of foam particles have sizes in a range of between 2 mm and 4 mms;
- mixing the plurality of foam particles with a glue to form a glue-particle mixture;
- measuring a weight of the glue-particle mixture into the mold;
- and
- applying heat and compression to the glue-particle mixture.
Dependencies are inferred from the claim text.