Pre-conditioned foam pad

a foam pad and preconditioning technology, applied in the field of cushioning articles, can solve the problems of broken or ruptured closed cell windows, and limited air flow through the foam, and achieve the effect of accelerating the aging of the unaged mattress assembly

a foam pad and preconditioning technology, applied in the field of cushioning articles, can solve the problems of broken or ruptured closed cell windows, and limited air flow through the foam, and achieve the effect of accelerating the aging of the unaged mattress assembly

US20100072676A1Active Publication Date: 2010-03-25DREAMWELL +1
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Examples

Experimental program
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Embodiment Construction

[0038]The systems and methods described herein include, among other things, systems and methods for processing and finishing a foam material for use in a mattress to provide a mattress foam material that has more consistent hardness over time and area. Although the systems and methods described herein are described with reference to use with a mattress or sleeping surface, it will be understood by those of skill in the art that the foam processing techniques and systems described herein may be applied in other applications including other furniture related applications for sofas, chairs, love seats, boat seats, and other applications.

[0039]Turning to FIG. 1, there is depicted a photomicrograph of an open-cell foam material. Foam material may include polyurethane foam manufactured from synthetic or natural raw materials or latex foam material. Polyurethane foam is typically made by introducing tiny expandable gas bubbles into a reacting mixture of a polyol, a polyisocyanate and other...

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Abstract

Mattresses and methods for processing a flexible foam material for use in a mattress to provide a mattress foam material that has more consistent firmness over time and area. The methods include pre-conditioning the foam pad or mattress by applying a force across a substantial portion of a major surface of the mattress to compress or stretch the height of the foam, the length of the foam, and / or the width of the foam to break or open closed cells. In certain embodiments, the force is applied by repeatedly pressing a platen against the foam pad or placing the foam pad between one or more rollers.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The present application claims the benefit of the filing dates of U.S. Provisional Application No. 61 / 192,575, filed on Sep. 19, 2008, and U.S. Provisional Application No. 61 / 204,727, filed on Jan. 9, 2009, which are incorporated herein by reference.FIELD OF THE INVENTION[0002]This invention generally relates to cushioning articles such as mattresses and methods for processing a flexible foam material for use in a cushioning article so that it has more consistent firmness over time and area.BACKGROUND OF THE INVENTION[0003]Today, furniture, and particularly bedding, manufacturers have developed sophisticated and reliable techniques for manufacturing high quality and durable mattresses. The industry is capable of providing mattresses that last for over ten years providing comfortable sleeping surfaces for all that time.[0004]As the industry strives to continue providing improved quality and reliability, one area being addressed is the abil...

Claims

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Application Information

Patent Timeline
25 Mar 2010
Publication
US20100072676A1
IPC
B32B38/18
CPC
A47C27/148; A47C27/15; A47C31/123; B29C44/5627; B29K2275/00; Y10T29/49826; B29L2031/751; B68G7/00
Inventors
GLADNEY, RICHARD F.; DEFRANKS, MICHAEL S.