Upcycled mattress nucleus of essential foam elements
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United States of America Patent
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Oct 12, 2021
Grant Date -
Jul 2, 2020
app pub date -
Dec 31, 2019
filing date -
Nov 1, 2011
priority date (Note) -
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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.
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