US20130111672A1 - Mattresses Having a Matrix Core of Foam Elements - Google Patents
Mattresses Having a Matrix Core of Foam Elements Download PDFInfo
- Publication number
- US20130111672A1 US20130111672A1 US13/666,253 US201213666253A US2013111672A1 US 20130111672 A1 US20130111672 A1 US 20130111672A1 US 201213666253 A US201213666253 A US 201213666253A US 2013111672 A1 US2013111672 A1 US 2013111672A1
- Authority
- US
- United States
- Prior art keywords
- mattress
- core
- inches
- foam
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
Definitions
- This invention relates generally to the field of mattresses.
- the invention relates to mattress that utilize a core made up of a matrix of foam elements.
- Spring mattresses have been in use for over 100 years. Existing spring mattresses use a variety of spring types to form their inner core. Perhaps the most common is the traditional wire spring assembly having a set of interconnected wire spring coils.
- cores made of a single material, such as a core constructed from a solid piece of latex or polyurethane.
- This invention relates to mattress using other types of cores.
- cores take advantage of reclaimed or repurposed materials that would otherwise be discarded (e.g., as being unusable cut sizes or foam densities after foam manufacturing runs).
- the invention provides a mattress that is constructed of a core comprising a matrix of foam pieces that are bonded together.
- the core has a thickness in the range from about 1.5 inches to about 10 inches, and more particularly from about 3 inches to about 8 inches, a density of about 4 pounds to 8 pounds per cubic foot, and an Indentation Force Deflection (IFD) of about 28 to 65.
- IFD Indentation Force Deflection
- the core may have a top surface and a bottom surface. A base layer is coupled to the bottom surface of the core, and a cushion layer is coupled to the top surface.
- the foam pieces may comprise polyurethane, urethane and the like.
- the cushion layer comprises a visco-elastic material.
- a top layer is positioned above the cushion layer.
- a flame or fire retardant sock (referred to as an FR sock) may also be provided to enclose the completed mattress. Per regulations, this provides a covering for the mattress that meets an open flame standard. Alternatively, a flame retardant or resistant fiber layer may be provided below quilting if desired.
- a cover also known as a ticking, is typically employed to envelope the core, the base layer and the cushion layer. The cover may also be either quilted (to form a pillow top mattress), a plush quilted or non-quilted.
- the invention provides an exemplary method for constructing a mattress.
- a loaf is formed by combining a plurality of foam pieces and a bonding material into a generally rectangular mold and applying heat.
- the resulting loaf has a top, a bottom and four sides.
- a rectangular section is cut from the loaf, and will typically have a thickness in the range from about 3 inches to about 8 inches.
- the resulting core may have a density in the range from about 4 pounds to about 8 pounds and an IFD in the range from about 28 to about 65.
- a base layer is attached to a bottom surface of the core, and a cushion layer is attached to a top surface of the core.
- a cover is placed about the mattress.
- the mattresses described herein may be useful as mattresses for conventional beds, but they may also be useful for mattresses used with a sleeper sofa, camper beds, yacht beds, cruise-ships beds, play mats, gym mats, camping pads, nap pads, or any other potential use where a core with a padded surface may be desirable.
- the term “mattress” as used herein is intended to encompass these and other appropriate uses.
- FIG. 1 illustrates a schematic cross sectional side view of one embodiment of a mattress according to the invention.
- FIG. 2 is an exploded schematic top perspective view of the mattress of FIG. 1 , showing various component layers, not necessarily to scale.
- FIG. 3 illustrates a schematic cross sectional side view of another embodiment of a mattress according to the invention.
- FIG. 4 illustrates a mattress according to one of the embodiments described herein, with a layer of ticking disposed over the foam core, base layer, and cushion layer.
- FIG. 5 illustrates a cross-sectional view of another mattress according to one embodiment of the invention.
- FIG. 6 illustrates the mattress of FIG. 5 , having various component layers rolled back at one corner.
- FIGS. 7-12 illustrate testing results for certain mattresses according to various embodiments of this invention.
- Embodiments of the invention provide various mattress that utilize a core made up of a matrix of foam pieces or elements that are bonded together.
- the core is relatively dense, significantly more dense than traditional polyurethane cores. This increased density provides a stronger and more durable core while providing a more comfortable feel.
- Another significant advantage of using a matrix of foam pieces is that such foam pieces may be repurposed or otherwise reclaimed materials. Not only is this friendly to the environment, it also significantly reduces the cost of the mattress.
- the core may be constructed to have a high density along with a durable construction to provide increased life.
- This matrix of foam pieces is also firm and is constructed of a variety of small urethane or other foam pieces (typically re-purposed foam pieces, for example new foam that cannot be cut into other pieces of the desired size or sections of foam that are not the desired density for other purposes, allowing the foam to be re-purposed in a new fashion) that are joined together using an adhesive, heat and steam that tend to increase the density.
- foam pieces typically re-purposed foam pieces, for example new foam that cannot be cut into other pieces of the desired size or sections of foam that are not the desired density for other purposes, allowing the foam to be re-purposed in a new fashion
- the core may be constructed to be relatively dense, has an IFD in the range from about 28 to about 65 and is relatively inexpensive.
- materials that may be used include polystyrene materials, polyurethane, densified fibers and the like.
- the IFD or Indentation Force Deflection, refers to the hardness or softness of the foam. For example, the higher the IFD, the firmer the foam.
- IFD is defined as the amount of force, in pounds, required to indent a fifty square inch, round indentor foot into a predefined foam specimen a certain percentage of the specimen's total thickness. IFD is specified as a number of pounds at a specific deflection percentage on a specific height foam sample, e.g., 25 pounds applied to 50 square inches at a 25% deflection on a four inch thick piece.
- a wide variety of optional layers may be coupled to the top and/or bottom surface of the core.
- another dense foam material may be coupled to the bottom of the core.
- a variety of layers may be placed on top of the core, including additional padding layers, ticking, foam, a quilted layer, or the like.
- one or more cushion layers may be placed above the core. These may be constructed of a material such as a polyurethane or latex foam, a visco-elastic or memory foam material, or the like. These additional padding layers may be used to provide the mattress with additional comfort and may be used alone or in various combinations. One or both sides of these cushion layers may be surface modified using various machining processes. Examples of surface modifications include convoluted, contoured, and the like. Other materials that may be used include fiber padding materials. Further, mattresses of the invention may include a layer of ticking that is a piece of fabric or quilting that envelopes the mattress as is known in the art. The ticking may comprise essentially any type of fabric or covering and may be sewn to form it around the core and other padding layers.
- Mattress 10 includes a core 12 that is constructed of a plurality of foam pieces that are bonded together to form a matrix.
- Core 12 typically has a thickness in the range from about 3 inches to about 8 inches, but may range anywhere from 1.5 inches to about 10 inches.
- One specific embodiment has a core that is about 4.5 inches to about 7.5 inches.
- the core thickness may range from about 3 inches to about 5 inches, and may specifically be about 4.5 inches.
- the core thickness may range from about 4 inches to about 6 inches, and may specifically be about 5.5 inches.
- the core thickness may range from about 6 inches to about 8 inches, and may specifically be about 7.5 inches.
- the core should be thick enough to provide appropriate support for sleeping and/or otherwise supporting one or more people, but should be thin enough that the mattress does not become unwieldy to transport or so large that sheets are difficult to secure in place about the mattress.
- the core may also have a density of about 4 pounds to 8 pounds per cubic foot, and an IFD of about 28 to 65. The density may be varied based upon the size and number of foam pieces used, as well as the type of binder used.
- Core 12 has a top surface 14 and a bottom surface 16 .
- One example showing how smaller foam pieces may be bonded to one another in order to form core 12 is shown in FIG. 5 , and such methods of manufacture are described further below.
- Base layer 18 may be Coupled to bottom surface 16 .
- the two may be coupled together by glue, a bonding material or the like.
- Base layer 18 will typically be a piece of foam that is less dense than core 12 and may have a thickness in the range from about 0.25 inch to about 4 inches. In a particular embodiment, the base layer thickness may range from about 0.5 to about 2 inches, and may specifically be about one inch. The density may be in the range from about 1 pound per cubic foot to about 2 pounds per cubic foot, with an IFD of about 28 to about 70. Base layer 18 in some cases serves to help hold together the foam pieces in the matrix, thus increasing the life of the mattress.
- cushion layer 20 Secured to top surface 16 is a cushion layer 20 .
- One exemplary material that may be used to construct cushion layer is a visco-elastic foam, gel viscoelastic foam, air ventilated viscofoam with enhanced breathing properties, memory foam, down feathers, synthetic down alternative, latex, any combination thereof, or any other appropriate cushion-like surface that adds comfort and padding to the mattress.
- the cushion layer 20 may be formed as a combination of one or more comfort layers.
- the density of this cushion layer may be in the range from about 2 pounds per cubic foot to about 6 pounds per cubic foot. In a particular embodiment, the density may range from about 2 pounds per cubic foot to about 5 pounds per cubic foot, and may specifically be about 3 pounds per cubic foot or about 3.5 pounds per cubic foot.
- the height of the cushion layer may be about 1 inch to about 6 inches, more specifically from about 1 inch to about 5 inches, and more specifically, from about 2 inches to about 4.5 inches, and even more particularly, about 4.5 inches.
- the cushion layer may have an IFD rating of about 6 to about 18.
- FIGS. 1 and 2 show a single layer of visco-elastic foam
- FIGS. 5 and 6 show other embodiments having multiple layers of visco-elastic foam or other cushion-like material.
- Cushion layer may also be a combination of air insulated viscofoam with enhanced ventilating properties so that it breathes more and keeps the sleeper cooler.
- one layer 20 may be a visco-elastic memory foam and another layer 24 may be a second visco-elastic memory foam layer or a gel visco-elastic memory foam layer.
- the first lower visco-elastic memory foam layer may be about 3 to about 3.5 inches thick and may have a density of about 3 to about 3.5 pounds per cubic foot.
- the second upper visco-elastic memory foam layer or gel visco-elastic memory foam layer may be about 1 to about 1.5 inches thick.
- a flame or fire retardant sock (referred to as an FR sock) may also be provided to enclose the completed mattress. Per regulations, this provides a covering for the mattress that meets an open flame standard. Alternatively, a flame retardant or resistant fiber layer may be provided below quilting if desired.
- a cover ticking 22 may be used to envelop the mattress. Ticking 22 comprises a fabric that is secured about the various layers. FIG. 4 shows a mattress that has been enveloped by a layer of ticking 22 .
- various other layers may be provided on mattress 10 to change the look and feel of the mattress. These could be included beneath the ticking 22 , such as with layer 24 , or above ticking 22 , such as in the case of an independent topper 26 . These additional layers may be surface modified, such as convoluted. Examples of materials that may be used for the additional layers include latex, gel materials, fibrous spacer materials, that may optionally include a gel material, and the like. Also, various backing materials and fire resistant layers or materials may be used as well.
- foam pieces are used. These may be of various shapes and sizes. Merely by way of example, these foam pieces may have a size in the range from about 0.25 inch by about 0.25 inch by about 0.25 inch to about 3 inches by about 3 inches by about 1 inch. Often, these may be pieces or remnants from other applications that can be repurposed rather than discarded. This often leads to the various sizes of pieces that may be used. For example, various pieces of remnant foams may be collected, then shredded down to smaller pieces. The individual pieces then need to be coated with a binder or resin, such as a polyurethane binder. This may be performed by feeding the pieces into a large container where the foam pieces are sprayed or otherwise mixed with the binder.
- a binder or resin such as a polyurethane binder
- the foam pieces are placed within a rectangular mold.
- This mold may have various sizes depending on the desired size of the mattress. Merely by way of example, the mold may have a size in the range from about 60 inches by about 80 inches, with a height of about 3 feet to 4 feet.
- multiple cores may be bonded together. For example, two cores that are the size of a twin mattress could be bonded together at their sides to obtain the size and shape of a king sized mattress.
- a compression member that may be driven by a piston is used to compress the foam pieces to the desired density within the mold.
- the density of the individual pieces will also contribute to the resulting density.
- the mold is then subjected to steam to cure the binder and allowed to cool.
- the resulting loaf is removed from the mold and has a rectangular shape. This loaf may be sliced into multiple layers in order to form separate cores. Additional timing to size may also be performed.
- Mattresses made according to the various embodiments described herein were subjected to various tests in order to determine the firmness and fatigue resistance of the mattresses.
- the tests conducted are general protocol in the bedding industry.
- First, the firmness of the mattress is scanned and measured prior to any fatigue test. For this test, a 15′′ circular plate is depressed into the bed in about nine locations, and the pounds of pressure required for the plate to press 75% into the mattress is measured. The plate then moves to 25% depression, which gives the IFD (indentation force deflection).
- a rollator which is a 3 foot, six-sided, 230 pounds log
- the mattress rests 24 hours and is scanned, which electronically measures any loss/gain of height.
- the IFD test is conducted again as well. Additional cycles of 25,000 cycles, 50,000 cycles, 75,000 cycles and 100,000 cycles are run, repeating the rest, scan & IFD test. It is believed that about 100,000 cycles approximates 10 years of use.
- FIG. 7 shows testing results from tests conducted on a mattress having the following parameters.
- FIG. 8 illustrates percentage changes in firmness of the mattress after such tests.
- Mattress type Green Choice Elegant 11′′ (Core: 6.5 inches+1 inch support foam layer as base layer; cushion layer: 3.5 inches (1.5 inch air insulated viscofoam with ventilating properties +2 inches of regular viscofoam above core)
- FIG. 9 shows exemplary results for selected tests conducted on a mattress having the following parameters.
- FIG. 10 illustrates percentage changes in firmness of the mattress after such tests.
- FIG. 11 shows exemplary results for selected tests conducted on a mattress having the following parameters.
- FIG. 12 illustrates percentage changes in firmness of the mattress after such tests.
Abstract
A mattress is constructed of a core comprising a matrix of foam pieces that are bonded together. The core has a thickness in the range from about 1.5 inches to about 10 inches, and more particularly from about 3 inches to about 8 inches, a density of about 4 pounds to 8 pounds per cubic foot, and an IFD of about 28 to 65. The core has a top surface and a bottom surface. A base layer is coupled to the bottom surface of the core, and a cushion layer is coupled to the top surface.
Description
- This application claims the benefit of U.S. Provisional Application Serial No. 61/554,413, filed Nov. 1, 2011, titled “Mattresses Having a Matrix Core of Foam Elements,” the entire contents of which are hereby incorporated by reference.
- This invention relates generally to the field of mattresses. In particular, the invention relates to mattress that utilize a core made up of a matrix of foam elements.
- Spring mattresses have been in use for over 100 years. Existing spring mattresses use a variety of spring types to form their inner core. Perhaps the most common is the traditional wire spring assembly having a set of interconnected wire spring coils.
- As manufacturing processes have improved, it is becoming more common to use other types of cores, including cores made of a single material, such as a core constructed from a solid piece of latex or polyurethane.
- This invention relates to mattress using other types of cores. Such cores take advantage of reclaimed or repurposed materials that would otherwise be discarded (e.g., as being unusable cut sizes or foam densities after foam manufacturing runs).
- In one embodiment, the invention provides a mattress that is constructed of a core comprising a matrix of foam pieces that are bonded together. The core has a thickness in the range from about 1.5 inches to about 10 inches, and more particularly from about 3 inches to about 8 inches, a density of about 4 pounds to 8 pounds per cubic foot, and an Indentation Force Deflection (IFD) of about 28 to 65. For convenience of discussion, the core may have a top surface and a bottom surface. A base layer is coupled to the bottom surface of the core, and a cushion layer is coupled to the top surface. In this way, remnant foam pieces that may otherwise be discarded may be used to form a relatively dense mattress core. For example, the foam pieces may comprise polyurethane, urethane and the like.
- In one aspect, the cushion layer comprises a visco-elastic material. In another aspect, a top layer is positioned above the cushion layer. A flame or fire retardant sock (referred to as an FR sock) may also be provided to enclose the completed mattress. Per regulations, this provides a covering for the mattress that meets an open flame standard. Alternatively, a flame retardant or resistant fiber layer may be provided below quilting if desired. Further, a cover, also known as a ticking, is typically employed to envelope the core, the base layer and the cushion layer. The cover may also be either quilted (to form a pillow top mattress), a plush quilted or non-quilted.
- In a further embodiment, the invention provides an exemplary method for constructing a mattress. In one step of the process, a loaf is formed by combining a plurality of foam pieces and a bonding material into a generally rectangular mold and applying heat. In this way, the resulting loaf has a top, a bottom and four sides. To form a core, a rectangular section is cut from the loaf, and will typically have a thickness in the range from about 3 inches to about 8 inches. The resulting core may have a density in the range from about 4 pounds to about 8 pounds and an IFD in the range from about 28 to about 65. A base layer is attached to a bottom surface of the core, and a cushion layer is attached to a top surface of the core. Typically, a cover is placed about the mattress.
- The mattresses described herein may be useful as mattresses for conventional beds, but they may also be useful for mattresses used with a sleeper sofa, camper beds, yacht beds, cruise-ships beds, play mats, gym mats, camping pads, nap pads, or any other potential use where a core with a padded surface may be desirable. The term “mattress” as used herein is intended to encompass these and other appropriate uses.
-
FIG. 1 illustrates a schematic cross sectional side view of one embodiment of a mattress according to the invention. -
FIG. 2 is an exploded schematic top perspective view of the mattress ofFIG. 1 , showing various component layers, not necessarily to scale. -
FIG. 3 illustrates a schematic cross sectional side view of another embodiment of a mattress according to the invention. -
FIG. 4 illustrates a mattress according to one of the embodiments described herein, with a layer of ticking disposed over the foam core, base layer, and cushion layer. -
FIG. 5 illustrates a cross-sectional view of another mattress according to one embodiment of the invention. -
FIG. 6 illustrates the mattress ofFIG. 5 , having various component layers rolled back at one corner. -
FIGS. 7-12 illustrate testing results for certain mattresses according to various embodiments of this invention. - Embodiments of the invention provide various mattress that utilize a core made up of a matrix of foam pieces or elements that are bonded together. The core is relatively dense, significantly more dense than traditional polyurethane cores. This increased density provides a stronger and more durable core while providing a more comfortable feel. Another significant advantage of using a matrix of foam pieces is that such foam pieces may be repurposed or otherwise reclaimed materials. Not only is this friendly to the environment, it also significantly reduces the cost of the mattress.
- Hence, the core may be constructed to have a high density along with a durable construction to provide increased life. This matrix of foam pieces is also firm and is constructed of a variety of small urethane or other foam pieces (typically re-purposed foam pieces, for example new foam that cannot be cut into other pieces of the desired size or sections of foam that are not the desired density for other purposes, allowing the foam to be re-purposed in a new fashion) that are joined together using an adhesive, heat and steam that tend to increase the density. One particularly useful method for constructing cores using such a process is described hereinafter.
- Further, the core may be constructed to be relatively dense, has an IFD in the range from about 28 to about 65 and is relatively inexpensive. Other types of materials that may be used include polystyrene materials, polyurethane, densified fibers and the like. The IFD, or Indentation Force Deflection, refers to the hardness or softness of the foam. For example, the higher the IFD, the firmer the foam. IFD is defined as the amount of force, in pounds, required to indent a fifty square inch, round indentor foot into a predefined foam specimen a certain percentage of the specimen's total thickness. IFD is specified as a number of pounds at a specific deflection percentage on a specific height foam sample, e.g., 25 pounds applied to 50 square inches at a 25% deflection on a four inch thick piece.
- A wide variety of optional layers may be coupled to the top and/or bottom surface of the core. For example, another dense foam material may be coupled to the bottom of the core. A variety of layers may be placed on top of the core, including additional padding layers, ticking, foam, a quilted layer, or the like.
- In some embodiments, one or more cushion layers may be placed above the core. These may be constructed of a material such as a polyurethane or latex foam, a visco-elastic or memory foam material, or the like. These additional padding layers may be used to provide the mattress with additional comfort and may be used alone or in various combinations. One or both sides of these cushion layers may be surface modified using various machining processes. Examples of surface modifications include convoluted, contoured, and the like. Other materials that may be used include fiber padding materials. Further, mattresses of the invention may include a layer of ticking that is a piece of fabric or quilting that envelopes the mattress as is known in the art. The ticking may comprise essentially any type of fabric or covering and may be sewn to form it around the core and other padding layers.
- Referring now to
FIGS. 1 and 2 , one embodiment of amattress 10 will be described.Mattress 10 includes a core 12 that is constructed of a plurality of foam pieces that are bonded together to form a matrix.Core 12 typically has a thickness in the range from about 3 inches to about 8 inches, but may range anywhere from 1.5 inches to about 10 inches. One specific embodiment has a core that is about 4.5 inches to about 7.5 inches. In a particular embodiment, the core thickness may range from about 3 inches to about 5 inches, and may specifically be about 4.5 inches. In an alternate embodiment, the core thickness may range from about 4 inches to about 6 inches, and may specifically be about 5.5 inches. In a further embodiment, the core thickness may range from about 6 inches to about 8 inches, and may specifically be about 7.5 inches. The core should be thick enough to provide appropriate support for sleeping and/or otherwise supporting one or more people, but should be thin enough that the mattress does not become unwieldy to transport or so large that sheets are difficult to secure in place about the mattress. - The core may also have a density of about 4 pounds to 8 pounds per cubic foot, and an IFD of about 28 to 65. The density may be varied based upon the size and number of foam pieces used, as well as the type of binder used.
Core 12 has atop surface 14 and abottom surface 16. One example showing how smaller foam pieces may be bonded to one another in order to formcore 12 is shown inFIG. 5 , and such methods of manufacture are described further below. - Coupled to
bottom surface 16 may be abase layer 18. The two may be coupled together by glue, a bonding material or the like.Base layer 18 will typically be a piece of foam that is less dense thancore 12 and may have a thickness in the range from about 0.25 inch to about 4 inches. In a particular embodiment, the base layer thickness may range from about 0.5 to about 2 inches, and may specifically be about one inch. The density may be in the range from about 1 pound per cubic foot to about 2 pounds per cubic foot, with an IFD of about 28 to about 70.Base layer 18 in some cases serves to help hold together the foam pieces in the matrix, thus increasing the life of the mattress. - Secured to
top surface 16 is acushion layer 20. One exemplary material that may be used to construct cushion layer is a visco-elastic foam, gel viscoelastic foam, air ventilated viscofoam with enhanced breathing properties, memory foam, down feathers, synthetic down alternative, latex, any combination thereof, or any other appropriate cushion-like surface that adds comfort and padding to the mattress. Thecushion layer 20 may be formed as a combination of one or more comfort layers. The density of this cushion layer may be in the range from about 2 pounds per cubic foot to about 6 pounds per cubic foot. In a particular embodiment, the density may range from about 2 pounds per cubic foot to about 5 pounds per cubic foot, and may specifically be about 3 pounds per cubic foot or about 3.5 pounds per cubic foot. The height of the cushion layer may be about 1 inch to about 6 inches, more specifically from about 1 inch to about 5 inches, and more specifically, from about 2 inches to about 4.5 inches, and even more particularly, about 4.5 inches. The cushion layer may have an IFD rating of about 6 to about 18.FIGS. 1 and 2 show a single layer of visco-elastic foam, andFIGS. 5 and 6 show other embodiments having multiple layers of visco-elastic foam or other cushion-like material. Cushion layer may also be a combination of air insulated viscofoam with enhanced ventilating properties so that it breathes more and keeps the sleeper cooler. - The various layers may have different densities and or IFD ratings. As shown in
FIG. 5 , in a particular embodiment with the cushion layer formed of two layers, onelayer 20 may be a visco-elastic memory foam and anotherlayer 24 may be a second visco-elastic memory foam layer or a gel visco-elastic memory foam layer. The first lower visco-elastic memory foam layer may be about 3 to about 3.5 inches thick and may have a density of about 3 to about 3.5 pounds per cubic foot. The second upper visco-elastic memory foam layer or gel visco-elastic memory foam layer may be about 1 to about 1.5 inches thick. Providing two layers in the cushion layer can add additional comfort to the mattress. - A flame or fire retardant sock (referred to as an FR sock) may also be provided to enclose the completed mattress. Per regulations, this provides a covering for the mattress that meets an open flame standard. Alternatively, a flame retardant or resistant fiber layer may be provided below quilting if desired. A cover ticking 22 may be used to envelop the mattress.
Ticking 22 comprises a fabric that is secured about the various layers.FIG. 4 shows a mattress that has been enveloped by a layer of ticking 22. - As shown in
FIG. 3 , various other layers may be provided onmattress 10 to change the look and feel of the mattress. These could be included beneath the ticking 22, such as withlayer 24, or above ticking 22, such as in the case of anindependent topper 26. These additional layers may be surface modified, such as convoluted. Examples of materials that may be used for the additional layers include latex, gel materials, fibrous spacer materials, that may optionally include a gel material, and the like. Also, various backing materials and fire resistant layers or materials may be used as well. - To construct
core 12, multiple foam pieces are used. These may be of various shapes and sizes. Merely by way of example, these foam pieces may have a size in the range from about 0.25 inch by about 0.25 inch by about 0.25 inch to about 3 inches by about 3 inches by about 1 inch. Often, these may be pieces or remnants from other applications that can be repurposed rather than discarded. This often leads to the various sizes of pieces that may be used. For example, various pieces of remnant foams may be collected, then shredded down to smaller pieces. The individual pieces then need to be coated with a binder or resin, such as a polyurethane binder. This may be performed by feeding the pieces into a large container where the foam pieces are sprayed or otherwise mixed with the binder. - After the pieces are coated with the binder, they are fed into a mold. To facilitate the construction of a core that is to be used for a mattress, the foam pieces are placed within a rectangular mold. This mold may have various sizes depending on the desired size of the mattress. Merely by way of example, the mold may have a size in the range from about 60 inches by about 80 inches, with a height of about 3 feet to 4 feet. For larger mattresses, multiple cores may be bonded together. For example, two cores that are the size of a twin mattress could be bonded together at their sides to obtain the size and shape of a king sized mattress. A compression member that may be driven by a piston is used to compress the foam pieces to the desired density within the mold. Also, it will be appreciated that the density of the individual pieces will also contribute to the resulting density. The mold is then subjected to steam to cure the binder and allowed to cool. The resulting loaf is removed from the mold and has a rectangular shape. This loaf may be sliced into multiple layers in order to form separate cores. Additional timing to size may also be performed.
- Mattresses made according to the various embodiments described herein were subjected to various tests in order to determine the firmness and fatigue resistance of the mattresses. The tests conducted are general protocol in the bedding industry. First, the firmness of the mattress is scanned and measured prior to any fatigue test. For this test, a 15″ circular plate is depressed into the bed in about nine locations, and the pounds of pressure required for the plate to press 75% into the mattress is measured. The plate then moves to 25% depression, which gives the IFD (indentation force deflection). Next, a rollator (which is a 3 foot, six-sided, 230 pounds log) rolls back and forth across center of mattress for about 10,000 cycles. The mattress rests 24 hours and is scanned, which electronically measures any loss/gain of height. The IFD test is conducted again as well. Additional cycles of 25,000 cycles, 50,000 cycles, 75,000 cycles and 100,000 cycles are run, repeating the rest, scan & IFD test. It is believed that about 100,000 cycles approximates 10 years of use.
- Exemplary results for selected tests are outlined in the attached figures.
FIG. 7 shows testing results from tests conducted on a mattress having the following parameters.FIG. 8 illustrates percentage changes in firmness of the mattress after such tests. - Mattress type: Green Choice Elegant 11″ (Core: 6.5 inches+1 inch support foam layer as base layer; cushion layer: 3.5 inches (1.5 inch air insulated viscofoam with ventilating properties +2 inches of regular viscofoam above core)
-
FIG. 9 shows exemplary results for selected tests conducted on a mattress having the following parameters.FIG. 10 illustrates percentage changes in firmness of the mattress after such tests. - Mattress type:
Green Choice Bliss 10″ (Core: 4.5″ ES Core+1″ support foam; cushion layer: 3.5″ 3 lbs ViscoElas Memory Foam+1″ ViscoElas Memory Foam topper) -
FIG. 11 shows exemplary results for selected tests conducted on a mattress having the following parameters.FIG. 12 illustrates percentage changes in firmness of the mattress after such tests. - Mattress type: Green Choice Relaxation 11″ (Core: 5.5″ ES Core+1″ support foam; cushion layer: 3″ 3 lbs ViscoElas Memory Foam+1.5″ Gel ViscoElas Memory Foam topper)
- The invention has now been described in detail for purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of the appended claims.
Claims (15)
1. A mattress comprising:
a core comprising a matrix of foam pieces that are bonded together, wherein the core has a thickness in the range from about 1.5 inches to about 10 inches, a density of about 4 pounds to 8 pounds, and an IFD of about 28 to 65, the core having a top surface and a bottom surface; and
a cushion layer coupled to the top surface.
2. The mattress of claim 1 , wherein the core thickness ranges from about 3 inches to about 8 inches'.
3. The mattress as in claim 1 , wherein the cushion layer comprises a visco-elastic material.
4. The mattress as in claim 1 , further comprising a top layer positioned above the cushion layer.
5. The mattress as in claim 1 , further comprising a cover enveloping the core, the base layer and the cushion layer.
6. The mattress as in claim 5 , wherein the cover is quilted.
7. The mattress as in claim 5 , wherein the cover has flame retardant or flare resistant features.
8. The mattress as in claim 1 , wherein the foam pieces comprise polyurethane, urethane, or a combination thereof
9. The mattress as in claim 1 , further comprising a base layer coupled to the bottom surface of the core.
10. The mattress as in claim 9 , wherein the base layer comprises a support foam layer.
11. A method for constructing a mattress, comprising:
forming a loaf by combining a plurality of foam pieces and a bonding material into a generally rectangular mold and applying heat, wherein the resulting loaf has a top, a bottom and four sides;
cutting a rectangular section from the loaf to form a core, wherein the rectangular section has a thickness in the range from about 1.5 inches to about 10 inches;
attaching a base layer to a bottom surface of the core;
attaching a cushion layer to a top surface of the core.
12. A method as in claim 11 , further comprising placing a cover about the mattress.
13. A method as in claim 11 , wherein the core has a density in the range from about 4 pounds to about 8 pounds and an IFD in the range from about 28 to about 65.
14. A method as in claim 11 , wherein the bonding material comprises a polyurethane binder.
15. A method as in claim 11 , wherein the plurality of foam pieces comprise repurposed pieces or remnants from other applications or from foam manufacturing runs that are otherwise unusable.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/666,253 US20130111672A1 (en) | 2011-11-01 | 2012-11-01 | Mattresses Having a Matrix Core of Foam Elements |
US15/729,722 US20180125258A1 (en) | 2011-11-01 | 2017-10-11 | Mattresses having a matrix core of foam elements |
US16/046,699 US10537186B2 (en) | 2011-11-01 | 2018-07-26 | Upcycled mattress nucleus of essential foam elements |
US16/731,993 US11140996B2 (en) | 2011-11-01 | 2019-12-31 | Upcycled mattress nucleus of essential foam elements |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161554413P | 2011-11-01 | 2011-11-01 | |
US13/666,253 US20130111672A1 (en) | 2011-11-01 | 2012-11-01 | Mattresses Having a Matrix Core of Foam Elements |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/729,722 Continuation US20180125258A1 (en) | 2011-11-01 | 2017-10-11 | Mattresses having a matrix core of foam elements |
Publications (1)
Publication Number | Publication Date |
---|---|
US20130111672A1 true US20130111672A1 (en) | 2013-05-09 |
Family
ID=48222688
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/666,253 Abandoned US20130111672A1 (en) | 2011-11-01 | 2012-11-01 | Mattresses Having a Matrix Core of Foam Elements |
US15/729,722 Abandoned US20180125258A1 (en) | 2011-11-01 | 2017-10-11 | Mattresses having a matrix core of foam elements |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/729,722 Abandoned US20180125258A1 (en) | 2011-11-01 | 2017-10-11 | Mattresses having a matrix core of foam elements |
Country Status (1)
Country | Link |
---|---|
US (2) | US20130111672A1 (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104068675A (en) * | 2014-07-26 | 2014-10-01 | 王志成 | Dual-purpose mattress |
CN104068676A (en) * | 2014-07-26 | 2014-10-01 | 王志成 | Mattress |
US20140352072A1 (en) * | 2013-05-30 | 2014-12-04 | Prime Medical, LLC | Operating Room Table Pad |
WO2015065504A1 (en) * | 2013-10-28 | 2015-05-07 | Davis Laura M | Low peak pressure body support |
US20150335168A1 (en) * | 2014-05-23 | 2015-11-26 | American Signature, Inc. | Composite Seat Cushion |
JP2016054932A (en) * | 2014-09-09 | 2016-04-21 | 株式会社イノアックリビング | Method of manufacturing legless chair |
US20170245664A1 (en) * | 2014-09-30 | 2017-08-31 | Tempur-Pedic Management, Llc | Dual density molded foam pillow |
US20180279795A1 (en) * | 2017-03-30 | 2018-10-04 | Kickball Concepts Llc | Mattress assemblies having nested, zipperless mattress ticking assemblies |
US20190053633A1 (en) * | 2011-11-01 | 2019-02-21 | Denver Mattress Co., Llc | Upcycled mattress nucleus of essential foam elements |
US20190200570A1 (en) * | 2018-01-03 | 2019-07-04 | Purple Innovation, Llc | Pet cushion |
US11019934B2 (en) * | 2017-05-30 | 2021-06-01 | Dreamwell, Ltd. | Active comfort controlled bedding systems |
US11202515B2 (en) | 2017-12-12 | 2021-12-21 | Dreamwell, Ltd. | Active comfort controlled bedding systems |
US11633049B1 (en) * | 2015-10-20 | 2023-04-25 | Justin James Waggoner | User configurable mattress system and method for customizing and repairing the same |
Citations (34)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2147362A (en) * | 1937-01-30 | 1939-02-14 | Milwaukee Saddlery Company | Cushioning material |
US2722268A (en) * | 1954-02-23 | 1955-11-01 | Kenneth E Green | Seat cushion |
US3900648A (en) * | 1974-03-18 | 1975-08-19 | Imre Jack Smith | Space filling material and method |
US4683246A (en) * | 1986-03-14 | 1987-07-28 | Wm. T. Burnett & Co., Inc. | Polyurethane foam-fiber composites |
US4801493A (en) * | 1980-07-23 | 1989-01-31 | Daniel Ferziger | Coated fabric and mattress ticking |
US4862539A (en) * | 1987-05-11 | 1989-09-05 | Bokich Robb B | Resilient structure |
US5397620A (en) * | 1993-04-05 | 1995-03-14 | Thomas D. Root | System and method for forming activity surface |
US5745940A (en) * | 1996-06-18 | 1998-05-05 | Roberts; Derek | Customized modular mattress and bedding |
US6159574A (en) * | 1994-06-03 | 2000-12-12 | Fagerdala World Foams Ab | Laminated visco-elastic support |
US6223371B1 (en) * | 1999-04-15 | 2001-05-01 | Steven J. Antinori | Mattress and method of manufacture |
US6290800B1 (en) * | 1999-12-02 | 2001-09-18 | Steven J. Antinori | Machine for and a method of manufacturing a laminate particularly adapted for bedding, padding, and upholstering |
US6378150B1 (en) * | 1999-02-25 | 2002-04-30 | Nhk Spring Co., Ltd. | Cushion member, method and apparatus for manufacturing the same |
US6574814B2 (en) * | 2000-03-14 | 2003-06-10 | L&P Property Management Company | Bedding or seating product having filled tube topper |
US6623847B2 (en) * | 1998-06-03 | 2003-09-23 | Paul M. Yates | Resilent cushion |
US6782575B1 (en) * | 2003-09-05 | 2004-08-31 | Steven J. Antinori | Mattress core and mattress providing pressure relief and minimizing body pressure |
US20050026528A1 (en) * | 2003-07-29 | 2005-02-03 | Forsten Herman Hans | Fire resistant fabric composite, process for fire-blocking a mattress and mattress set, and a mattress and mattress set fire-blocked thereby |
US20050076446A1 (en) * | 2003-10-14 | 2005-04-14 | Tempur World, Inc. | Pillow top for a cushion |
US20050084667A1 (en) * | 1994-06-03 | 2005-04-21 | Tempur World, Inc. | Laminated visco-elastic support |
US20050095936A1 (en) * | 2004-09-02 | 2005-05-05 | Jones Walter G. | Upholstery panels with fire resistant backing layer |
US20050115001A1 (en) * | 2003-11-29 | 2005-06-02 | Bodet & Horst Gmbh & Co. Kg | Protective cover for bedding or bedding equipped with protective cover |
US20050166330A1 (en) * | 2004-01-31 | 2005-08-04 | Williams Carla M. | Particulate filler mattress |
US6928678B1 (en) * | 2004-02-17 | 2005-08-16 | Heng-Tai Chang | Transparent apertured pillow, filled with foam blocks |
US20060272098A1 (en) * | 2005-06-03 | 2006-12-07 | Hochschild Arthur A | Composite foam mattress assembly |
US20060288490A1 (en) * | 2005-06-24 | 2006-12-28 | Tempur World, Llc | Reticulated material body support and method |
US7255917B2 (en) * | 2001-12-11 | 2007-08-14 | Mike Rochlin, legal representative | Reticulated open cell filling material |
US20080060137A1 (en) * | 2004-05-07 | 2008-03-13 | Wenstrup David E | Heat and flame shield |
US20080263774A1 (en) * | 2007-04-24 | 2008-10-30 | Zinus Inc. | Flame-resistant mattress rejuvenator |
US7461424B2 (en) * | 2005-11-23 | 2008-12-09 | Wayne Belisle | Method and apparatus for a pillow including foam pieces of various sizes |
US20090149101A1 (en) * | 2005-08-22 | 2009-06-11 | Sytz Ronald M | Fire barrier fabric for use with articles |
US20100223734A1 (en) * | 2009-03-04 | 2010-09-09 | Zinus Inc. | Symmetrical pressure relief foam mattress |
US20110067183A1 (en) * | 2009-09-18 | 2011-03-24 | Hawkins Steven D | Cushioning device and method of manufacturing |
US20110252572A1 (en) * | 2010-04-19 | 2011-10-20 | Leigh Morrison | Multi-layer multi-material foam mattresses |
US8141957B2 (en) * | 2008-12-15 | 2012-03-27 | La-Z-Boy Incorporated | Cushion with plural zones of foam |
US20120258643A1 (en) * | 2009-10-13 | 2012-10-11 | Lenzing Aktiengesellschaft | Flame-retardant lyocell fibers and use thereof in flame barriers |
-
2012
- 2012-11-01 US US13/666,253 patent/US20130111672A1/en not_active Abandoned
-
2017
- 2017-10-11 US US15/729,722 patent/US20180125258A1/en not_active Abandoned
Patent Citations (37)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2147362A (en) * | 1937-01-30 | 1939-02-14 | Milwaukee Saddlery Company | Cushioning material |
US2722268A (en) * | 1954-02-23 | 1955-11-01 | Kenneth E Green | Seat cushion |
US3900648A (en) * | 1974-03-18 | 1975-08-19 | Imre Jack Smith | Space filling material and method |
US4801493A (en) * | 1980-07-23 | 1989-01-31 | Daniel Ferziger | Coated fabric and mattress ticking |
US4683246A (en) * | 1986-03-14 | 1987-07-28 | Wm. T. Burnett & Co., Inc. | Polyurethane foam-fiber composites |
US4862539A (en) * | 1987-05-11 | 1989-09-05 | Bokich Robb B | Resilient structure |
US5397620A (en) * | 1993-04-05 | 1995-03-14 | Thomas D. Root | System and method for forming activity surface |
US6159574A (en) * | 1994-06-03 | 2000-12-12 | Fagerdala World Foams Ab | Laminated visco-elastic support |
US20050084667A1 (en) * | 1994-06-03 | 2005-04-21 | Tempur World, Inc. | Laminated visco-elastic support |
US6541094B1 (en) * | 1994-06-03 | 2003-04-01 | Tempur World, Inc. | Laminated visco-elastic support |
US5745940A (en) * | 1996-06-18 | 1998-05-05 | Roberts; Derek | Customized modular mattress and bedding |
US6623847B2 (en) * | 1998-06-03 | 2003-09-23 | Paul M. Yates | Resilent cushion |
US6378150B1 (en) * | 1999-02-25 | 2002-04-30 | Nhk Spring Co., Ltd. | Cushion member, method and apparatus for manufacturing the same |
US6223371B1 (en) * | 1999-04-15 | 2001-05-01 | Steven J. Antinori | Mattress and method of manufacture |
US6290800B1 (en) * | 1999-12-02 | 2001-09-18 | Steven J. Antinori | Machine for and a method of manufacturing a laminate particularly adapted for bedding, padding, and upholstering |
US6574814B2 (en) * | 2000-03-14 | 2003-06-10 | L&P Property Management Company | Bedding or seating product having filled tube topper |
US7255917B2 (en) * | 2001-12-11 | 2007-08-14 | Mike Rochlin, legal representative | Reticulated open cell filling material |
US20050026528A1 (en) * | 2003-07-29 | 2005-02-03 | Forsten Herman Hans | Fire resistant fabric composite, process for fire-blocking a mattress and mattress set, and a mattress and mattress set fire-blocked thereby |
US6782575B1 (en) * | 2003-09-05 | 2004-08-31 | Steven J. Antinori | Mattress core and mattress providing pressure relief and minimizing body pressure |
US20050076446A1 (en) * | 2003-10-14 | 2005-04-14 | Tempur World, Inc. | Pillow top for a cushion |
US7707670B2 (en) * | 2003-10-14 | 2010-05-04 | Tempur-Pedic Management, Inc. | Pillow top for a cushion |
US20050115001A1 (en) * | 2003-11-29 | 2005-06-02 | Bodet & Horst Gmbh & Co. Kg | Protective cover for bedding or bedding equipped with protective cover |
US20050166330A1 (en) * | 2004-01-31 | 2005-08-04 | Williams Carla M. | Particulate filler mattress |
US6928678B1 (en) * | 2004-02-17 | 2005-08-16 | Heng-Tai Chang | Transparent apertured pillow, filled with foam blocks |
US20080060137A1 (en) * | 2004-05-07 | 2008-03-13 | Wenstrup David E | Heat and flame shield |
US20050095936A1 (en) * | 2004-09-02 | 2005-05-05 | Jones Walter G. | Upholstery panels with fire resistant backing layer |
US20060272098A1 (en) * | 2005-06-03 | 2006-12-07 | Hochschild Arthur A | Composite foam mattress assembly |
US20060288490A1 (en) * | 2005-06-24 | 2006-12-28 | Tempur World, Llc | Reticulated material body support and method |
US20060288491A1 (en) * | 2005-06-24 | 2006-12-28 | Mikkelsen Tom D | Reticulated material body support and method |
US20090149101A1 (en) * | 2005-08-22 | 2009-06-11 | Sytz Ronald M | Fire barrier fabric for use with articles |
US7461424B2 (en) * | 2005-11-23 | 2008-12-09 | Wayne Belisle | Method and apparatus for a pillow including foam pieces of various sizes |
US20080263774A1 (en) * | 2007-04-24 | 2008-10-30 | Zinus Inc. | Flame-resistant mattress rejuvenator |
US8141957B2 (en) * | 2008-12-15 | 2012-03-27 | La-Z-Boy Incorporated | Cushion with plural zones of foam |
US20100223734A1 (en) * | 2009-03-04 | 2010-09-09 | Zinus Inc. | Symmetrical pressure relief foam mattress |
US20110067183A1 (en) * | 2009-09-18 | 2011-03-24 | Hawkins Steven D | Cushioning device and method of manufacturing |
US20120258643A1 (en) * | 2009-10-13 | 2012-10-11 | Lenzing Aktiengesellschaft | Flame-retardant lyocell fibers and use thereof in flame barriers |
US20110252572A1 (en) * | 2010-04-19 | 2011-10-20 | Leigh Morrison | Multi-layer multi-material foam mattresses |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11140996B2 (en) | 2011-11-01 | 2021-10-12 | Denver Mattress Co., Llc | Upcycled mattress nucleus of essential foam elements |
US10537186B2 (en) * | 2011-11-01 | 2020-01-21 | Denver Mattress Co., Llc | Upcycled mattress nucleus of essential foam elements |
US20190053633A1 (en) * | 2011-11-01 | 2019-02-21 | Denver Mattress Co., Llc | Upcycled mattress nucleus of essential foam elements |
US20140352072A1 (en) * | 2013-05-30 | 2014-12-04 | Prime Medical, LLC | Operating Room Table Pad |
WO2015065504A1 (en) * | 2013-10-28 | 2015-05-07 | Davis Laura M | Low peak pressure body support |
US20150335168A1 (en) * | 2014-05-23 | 2015-11-26 | American Signature, Inc. | Composite Seat Cushion |
CN104068676A (en) * | 2014-07-26 | 2014-10-01 | 王志成 | Mattress |
CN104068675A (en) * | 2014-07-26 | 2014-10-01 | 王志成 | Dual-purpose mattress |
JP2016054932A (en) * | 2014-09-09 | 2016-04-21 | 株式会社イノアックリビング | Method of manufacturing legless chair |
US20170245664A1 (en) * | 2014-09-30 | 2017-08-31 | Tempur-Pedic Management, Llc | Dual density molded foam pillow |
US11633049B1 (en) * | 2015-10-20 | 2023-04-25 | Justin James Waggoner | User configurable mattress system and method for customizing and repairing the same |
US20180279795A1 (en) * | 2017-03-30 | 2018-10-04 | Kickball Concepts Llc | Mattress assemblies having nested, zipperless mattress ticking assemblies |
US11019934B2 (en) * | 2017-05-30 | 2021-06-01 | Dreamwell, Ltd. | Active comfort controlled bedding systems |
US11202515B2 (en) | 2017-12-12 | 2021-12-21 | Dreamwell, Ltd. | Active comfort controlled bedding systems |
US11957251B2 (en) | 2017-12-12 | 2024-04-16 | Dreamwell, Ltd. | Active comfort controlled bedding systems |
US20190200570A1 (en) * | 2018-01-03 | 2019-07-04 | Purple Innovation, Llc | Pet cushion |
Also Published As
Publication number | Publication date |
---|---|
US20180125258A1 (en) | 2018-05-10 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20180125258A1 (en) | Mattresses having a matrix core of foam elements | |
US11019936B2 (en) | Pocketed foam systems and methods | |
US11140996B2 (en) | Upcycled mattress nucleus of essential foam elements | |
US6574814B2 (en) | Bedding or seating product having filled tube topper | |
EP3562351B1 (en) | Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same | |
US7284494B2 (en) | High comfort mattresses having fiberballs | |
US4207636A (en) | Cushion construction | |
US6952850B2 (en) | No-flip mattress systems and methods | |
US20110099722A1 (en) | Mattresses with reinforcement inserts and densified stitch zones | |
US20190038043A1 (en) | Dual density systems and methods for bedding applications | |
US20110061168A1 (en) | Sleep support surface that includes a layer with large diameter cleaving | |
US6895620B1 (en) | High comfort mattresses and methods for constructing them | |
US20110047708A1 (en) | Mattresses with heat dissipation | |
US20210045539A1 (en) | Posturized Pocketed Spring Comfort Layer | |
US20050000026A1 (en) | Tray support for a mattress | |
US2742652A (en) | Cushions and cushioning material | |
WO2019209823A1 (en) | Furniture cushion | |
CA2778640A1 (en) | Composite memory foam and uses thereof | |
US20120189809A1 (en) | Laminated foam pad | |
CN114450247A (en) | Soft cushion comfort member comprising lignocellulosic fibers | |
JP3239733U (en) | Hardened high resilience overlay mattresses, hardened high resilience mattresses, hardened high resilience cushions and hardened high resilience pillows | |
US20190281993A1 (en) | Heat-Resistant Sleep Articles |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: DENVER MATTRESS CO., LLC, COLORADO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:RENSINK, ROBERT;REEL/FRAME:029234/0933 Effective date: 20121102 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION |