An agglomerated foam layer for a mattress and a mattress comprising such layer

Abstract

The present disclosure is within the technical area of layers of foam for mattresses and mattresses formed of a plurality of layers, for a person to lay on and rest, typically being provided on a bed. It includes an agglomerated foam layer for a mattress, the layer comprising foam pieces and a binding agent, wherein prior to agglomeration the foam has been subjected to compression to a volume corresponding to 65 to 95 % of its total volume before compression. It further includes a mattress comprising a plurality of layers, the plurality of layers including an inner layer comprising the agglomerated foam layer of any of the preceding claims and at least two enveloping layers, the agglomerated layer being provided between the two enveloping layers, wherein each of the enveloping layers comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

Description

TECHNICAL AREA

[0001] The present disclosure is within the technical area of layers of foam for mattresses and mattresses formed of a plurality of layers, for a person to lay on and rest, typically being provided on a bed.PRIOR ART

[0002] Mattresses are a type of product which, although seemingly consisting of a single piece, are composed of multiple elements.

[0003] Particularly, mattresses made of several layers not only are composed of such several layers as they may also comprise springs and corresponding enclosures, as well as covering materials such as stretch fabric.

[0004] The ability to assemble and disassemble the mattresses into and from several elements is, thus a challenge. Mattresses known in the art require the production of layers from raw materials and / or fail in the ability to disassemble again into the several elements, for subsequent recycling.

[0005] The solution of the present disclosure provides a layer for a mattress and a mattress which include recycled elements and which enable eased production and transport.

[0006] Agglomerated foam is known in prior art in association with mattresses that are too firm and uncomfortable, composed of surplus foams without selection and without concern for comfort, and of very high hardness and density.

[0007] Moreover, intense and / or prolonged compression of agglomerated foams causes some cells to collapse, resulting in plastic or permanent deformation. In this way, mattresses known in the art having agglomerated foam layers and that are rolled or folded and rolled have a time limit for being kept rolled in order to avoid plastic or permanent deformation. Within that period, the foams lose some of their physical properties, both in terms of cellular structure and foam hardness, as well as volume. Typically, this condition leads to such mattresses being produced and transported only in flat format.

[0008] These changes are even more significant in low-density and low-quality foams, commonly present in agglomerated foams, as they have greater fragility in their cell walls.

[0009] The solution of the present disclosure overcomes such issues, by providing an agglomerated foam layer suitable for comfort mattress solutions and which, when provided in a mattress, allows such mattress to be rolled or folded.SUMMARY OF THE DISCLOSURE

[0010] The present disclosure includes an agglomerated foam layer for a mattress. The layer comprises foam pieces and a binding agent, wherein prior to agglomeration the foam has been subjected to compression to a volume corresponding to 65 to 95 % of its total volume before compression.

[0011] The said compression may have been performed to a volume corresponding 70 to 95 % of the total volume of the foam before compression, optionally 75 to 85 %.

[0012] The compression may have been maintained during 300 to 2,200 hours, optionally 720 to 1,440 hours.

[0013] The pieces of foam may have a density of 15-60 kg.m -3< , optionally a density of 40-60 kg.m -3< , optionally a density of 45-55 kg.m -3< , optionally a density of 46-54 kg.m -3< , optionally a density of 47-53 kg.m -3< , optionally a density of 48-52 kg.m -3< , optionally a density of 49-51 kg.m -3< , optionally a density of 50 kg.m -3< .

[0014] The thickness of the agglomerated foam layer may be within the range of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0015] The pieces of foam are polyurethane and / or polyurethane repolyol foam pieces.

[0016] The binding agent may be present in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25%.

[0017] The foam pieces may have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , optionally between 0.25 and 5 cm 3< , optionally between 0.25 and 2 cm 3< .

[0018] The present disclosure may further comprise a mattress comprising a plurality of layers. The plurality of layers may include an inner layer comprising the agglomerated foam layer of the present disclosure and at least two enveloping layers, the agglomerated layer being provided between the two enveloping layers, wherein each of the enveloping layers comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

[0019] For each enveloping layer, the enveloping layer may have when composed of a standard foam, a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< , when composed of a high resilience foam, a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< .

[0020] For each enveloping layer, the enveloping layer may have when comprising a standard foam or being entirely composed of a standard foam, a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm.

[0021] The mattress may further comprise a spring portion provided between two layers.

[0022] The spring portion may be a pocket spring portion, and an enclosure of the pocket springs may be formed of agglomerated foam.

[0023] The mattress may comprise more than one inner layer, each inner layer being provided between two enveloping layers. A same enveloping layer may be a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress.

[0024] An inner layer may be a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions.

[0025] The mixed inner layer may comprise two agglomerated foam portions and three standard foam portions, the agglomerated foam portions alternating with the standard foam portions along one of the length or the width of the layer.

[0026] A first layer may have portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, may also have portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0027] The mattress may comprise further layers provided above or below the inner layer and the enveloping layers in the set of layers, the further layers being composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam.

[0028] The total thickness of the mattress may be within the range of 15-35 cm.

[0029] The total length of the mattress may be within the range of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm.

[0030] The total width of the mattress may be within the range of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm.

[0031] One of the enveloping layers may be a non-woven fabric sheet layer, the mattress further comprising one layer formed of springs adjacently provided to the non-woven fabric sheet layer and forming a composed spring layer with non-woven fabric sheet layer.

[0032] The present disclosure further comprises the use of the agglomerated foam layer of the present disclosure as a layer in a mattress.

[0033] The present disclosure may further comprise the use of the mattress of the present disclosure rolled, folded or folded and rolled and packaged in vacuum within a plastic cover.

[0034] The present disclosure may further comprise a method of producing an agglomerated foam layer for a mattress, the method comprising compressing foam to obtain compressed foam pieces by providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression, or providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces, agglomerating the foam pieces by means of bonding with a binding agent, and thereby obtaining an agglomerated foam layer or obtaining an agglomerated foam block and cutting such block to obtain a foam layer for a mattress.

[0035] The method of producing an agglomerated foam layer may be such that the compression is to a volume corresponding 70 to 95 % of the total volume of the foam before compression, optionally 75 to 85 %.

[0036] The method of producing an agglomerated foam layer may be such that the compression is performed during 300 to 2,200 hours, optionally 720 to 1,440 hours.

[0037] The method of producing an agglomerated foam layer may be such that the agglomerated foam comprises a plurality of pieces with a density of 15-60 kg.m -3< , optionally a density of 40-60 kg.m -3< , optionally a density of 45-55 kg.m -3< , optionally a density of 46-54 kg.m -3< , optionally a density of 47-53 kg.m -3< , optionally a density of 48-52 kg.m -3< , optionally a density of 49-51 kg.m -3< , optionally a density of 50 kg.m -3< .

[0038] The method of producing an agglomerated foam layer may be such that the resulting thickness is of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0039] The method of producing an agglomerated foam layer may be such that the pieces of foam are polyurethane and / or polyurethane repolyol foam pieces.

[0040] The method of producing an agglomerated foam layer may be such that in agglomeration the binding agent is provided in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25%.

[0041] The method of producing an agglomerated foam layer may be such that the foam pieces have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , optionally between 0.25 and 5 cm 3< , optionally between 0.25 and 2 cm 3< , optionally the method comprising shredding the foam portion to pieces having an average volume comprised between 0.15 and 25 cm 3< , and optionally between 0.5 and 5 cm 3< .

[0042] The present disclosure may further comprise a method of producing a mattress, the method comprising performing the method of producing an agglomerated foam layer of the present disclosure, thereby obtaining an agglomerated foam layer, providing two enveloping layers, each enveloping layer comprising a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet, providing the agglomerated foam layer between the two enveloping layers.

[0043] The method of producing a mattress may be such that, for each enveloping layer, when composed of a standard foam, has a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< , when composed of a high resilience foam, has a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< .

[0044] The method of producing a mattress may be such that, for each enveloping layer, when comprising a standard foam or being entirely composed of a standard foam, has a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, has a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm.

[0045] The method of producing a mattress may be such that it further comprises providing a spring portion between two layers.

[0046] The method of producing a mattress may be such that the spring portion is a pocket spring portion, the method comprising forming an enclosure of the pocket springs of agglomerated foam.

[0047] The method of producing a mattress may be such that it comprises providing more than one inner layer, each inner layer being provided between two enveloping layers. A same enveloping layer may be a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress.

[0048] The method of producing a mattress may be such that an inner layer is provided as a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions.

[0049] The method of producing a mattress may be such that the mixed inner layer is formed by means of two agglomerated foam portions and three standard foam portions, the agglomerated foam portions alternating with the standard foam portions along one of the length or the width of the layer.

[0050] The method of producing a mattress may be such that a first layer is formed with portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, is formed with portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0051] The method of producing a mattress may be such that it comprises providing further layers above or below the inner layer and the enveloping layers in the set of layers, the further layers being composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam.

[0052] The method of producing a mattress may be such that the total thickness of the mattress is of 15-35 cm.

[0053] The method of producing a mattress may be such that the total length of the mattress is of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm.

[0054] The method of producing a mattress may be such that the total width of the mattress is of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm.

[0055] The method of producing a mattress may be such that one of the enveloping layers is a non-woven fabric sheet layer, the mattress further comprising one layer formed of springs adjacently provided to the non-woven fabric sheet layer and forming a composed spring layer with non-woven fabric sheet layer.

[0056] The present disclosure may further comprise a method of packaging a mattress, the method including, providing a mattress according to the present disclosure or performing the method of producing a mattress of the present disclosure, thereby obtaining a mattress, rolling, folding or folding and rolling the mattress, enveloping the rolled, folded or folded and rolled mattress in a plastic cover,

[0057] The method of packaging a mattress may further comprise providing a vacuum within the plastic covered rolled, folded or folded and rolled mattress.DESCRIPTION OF THE FIGURES

[0058] Figure 1 - A representation of a mattress according to example M1 of a mattress according to the present disclosure. Figure 2 - A representation of a mattress according to example M2 of a mattress according to the present disclosure. Figure 3 - A representation of a mattress according to example M3 of a mattress according to the present disclosure. Figure 4 - A representation of a mattress according to example M4 of a mattress according to the present disclosure. Figure 5 - A representation of a mattress according to example M5 of a mattress according to the present disclosure. DETAILED DESCRIPTION

[0059] The present disclosure includes an agglomerated foam layer for a mattress. The layer comprises foam pieces and a binding agent.

[0060] Agglomerated foam, also referred to as rebonded foam, is a composite material formed by combining shredded or granulated pieces of polyurethane foam with an adhesive binding agent. Such combination may be performed under compression.

[0061] The agglomerated foam layer thus is formed as a unitary assembly of the pieces of foam, bound by the binding agent.

[0062] Compression to a volume corresponding to 65 to 95 % (optionally to 70 to 95 % or 75 to 85 % of the total volume of the foam before compression) of its total volume before compression means that the ensemble that is compressed, be it a plurality of foam pieces or a whole portion of foam which is subsequently shredded of granulated, is compressed to a volume which corresponds to 65 to 95 % of the volume of such ensemble prior to being compression.

[0063] Such compression of the foam material, prior to agglomeration, allows that when forming a layer which is provided within a mattress, such mattress may be rolled or folded, resulting in no breakage of the agglomerated foam layer. The prior compression of the foam material which will then form an agglomerated foam removes the cellular fragilities of such foam surplus.

[0064] This process makes their characteristics more uniform, ensuring superior quality after the mattress in which such layer is provided is unrolled.

[0065] The compression is performed temporarily, being maintained during 300 to 2,200 hours or 720 to 1,440 hours, to provide an enhanced mattress.

[0066] The foam, prior to compression, may have a density within a range of 15-60 kg.m -3< , 40-60 kg.m -3< , 45-55 kg.m -3< , 46-54 kg.m -3< , 47-53 kg.m -3< , 48-52 kg.m -3< , 49-51 kg.m -3< , or 50 kg.m -3< . Thus, an agglomerated foam layer may comprise foam pieces such that, prior to compression, each of the pieces had a density within one of the said ranges. While consisting of foam surplus potentially from different sources, the density of each of the pieces may be different from the density of the other pieces.

[0067] The pieces of foam are polyurethane and / or polyurethane repolyol foam based pieces. Repolyol is a recycled polyol material derived from the chemical recycling of polyurethane (PU) foam sourced from foam production waste and end-of-life products, such as mattresses and upholstered furniture.

[0068] The foam pieces may have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , 0.25 and 5 cm 3< , or 0.25 and 2 cm 3< . An agglomerated foam layer may comprise agglomerated pieces such that, prior to compression, each of the pieces had a volume within one of the said ranges. While consisting of foam surplus potentially from different sources, the volume of each of the pieces may be different from the volume of the other pieces.

[0069] Reference is made to the mattress of the present disclosure. It comprises a plurality of layers which may include an inner layer comprising the agglomerated foam layer of the present disclosure and at least two enveloping layers, the agglomerated layer being provided between the two enveloping layers, wherein each of the enveloping layers comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

[0070] The standard foam has a density of 20-40 kg.m -3< or of 25-30 kg.m -3< . The high resilience foam has a density of 20-40 kg.m -3< or of 25-30 kg.m -3< . The memory foam has a density of 30-100 kg.m -3< or of 40-70 kg.m -3< .

[0071] Indentation Load Deflection (ILD) refers to the measurement of a force required to compress a specified area of a material, particularly a foam material, to a predetermined percentage of its original thickness. This parameter is expressed in units of force and serves as an indicator of the firmness or stiffness of a material.

[0072] The standardized testing procedure for measuring ILD, as outlined in ISO 2439:2008 Method B, is specifically designed for flexible cellular materials such as polyurethane foam. This method involves compressing a foam sample to 40% of its original thickness at a constant speed and for a specified hold time. The force required to achieve and maintain the specified 40% compression is measured and recorded, providing a consistent and reproducible assessment of the hardness characteristics of the material.

[0073] The standard foam is such that it has an ILD of 10-70 (lbs). The high resilience foam is such that it has an ILD of 15-50. The memory foam is such that it has an ILD of 10-25.

[0074] The thickness of enveloping layers may be adapted to the corresponding agglomerated foam layer and / or the desired characteristics of the mattress, including total thickness. Thickness may also be referred to as height, as it corresponds to the dimension which is typically vertically aligned. Each enveloping layer may have when comprising a standard foam or being entirely composed of a standard foam, a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm.

[0075] The mattress may further comprise a spring portion provided between two layers. The spring portion may be a pocket spring portion, and an enclosure of the pocket springs may be formed of agglomerated foam. The agglomerated foam may be obtained according to the method of the present disclosure, such that it comprises compressing foam to obtain compressed foam pieces by providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression, or providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces, agglomerating the foam pieces by means of bonding with a binding agent, and the agglomeration being such that an agglomerated foam enclosure for pocket springs is obtained by means of cutting the agglomerated foam block.

[0076] The mattress may comprise more than one inner layer, each inner layer being provided between two enveloping layers. A same enveloping layer may be a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress. Thus, three enveloping layers may envelop two inner layers, wherein one of the enveloping layers is shared by the two inner layers.

[0077] As is the case of the mattresses of Figures 4 and 5, an inner layer may be a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions. Each agglomerated foam portion and each standard foam portion may extend along the whole width of the mattress, wherein agglomerated foam portions and standard foam portions are intercalated.

[0078] A mixed inner layer may comprise two agglomerated foam portions and three standard foam portions, as is the case of the mattresses of Figures 4 and 5. The agglomerated foam portions alternating with the standard foam portions along one of the length or the width (case of Figures 4 and 5) of the layer.

[0079] As is the case with the mattresses of Figures 2 and 3, a first layer may have portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, may also have portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0080] The mattress may comprise further layers provided above or below the inner layer and the enveloping layers in the set of layers, the further layers being composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam.

[0081] The total thickness of the mattress, formed by the whole assembly of layers or the whole assembly of layers and a cover, for instance a stretch fabric cover, may be within the range of 15-35cm.

[0082] The total length of the mattress may be within the range of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm. Each layer has a length which corresponds to the length of the mattress.

[0083] The total width of the mattress may be within the range of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm. Each layer has a width which corresponds to the width of the mattress.

[0084] One of the enveloping layers may be a non-woven fabric sheet layer, the mattress further comprising one layer formed of springs adjacently provided to the non-woven fabric sheet layer and forming a composed spring layer with non-woven fabric sheet layer, as is the case of the mattresses of Figures 1 and 4.

[0085] Reference is made to the method of producing an agglomerated foam layer for a mattress of the present disclosure.

[0086] Two embodiments for obtaining compressed granulated foam pieces may be provided. Foam is polyurethane foam and / or polyurethane repolyol foam.

[0087] Compressing foam to obtain compressed foam pieces may include providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression.

[0088] Alternatively, compressing foam to obtain compressed foam pieces may include providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces. Such alternative provides a more even material, as the compression stress is better provided to all of the compressed whole assembly, when compared to the compression of a foam pieces assembly. The foam portion is a whole foam portion, contrarily to the first embodiment, in which the foam is already granulated.

[0089] Whichever is the case, the foam used to obtain the agglomerated foam layer has a density of 15-60 kg.m -3< , 40-60 kg.m -3< , 45-55 kg.m -3< , 46-54 kg.m -3< , 47-53 kg.m -3< , 48-52 kg.m -3< , 49-51 kg.m -3< , or 50 kg.m -3< . Thus, either the foam portion or the pieces of the ensemble of shredded or granulated foam pieces have a density within such range.

[0090] In the case of the ensemble of shredded or granulated foam pieces, and since they consist of foam surplus potentially from different sources, the density of each of the pieces may be different from the density of the other pieces. Thus, the method is such that a resulting agglomerated foam layer may comprise foam pieces such that, prior to compression, each of the pieces had a density within one of the said ranges.

[0091] In the case of the foam portion, it consists of a whole foam portion. Thus, the density of the foam portion is substantially the same along the whole foam portion, and is within the said ranges.

[0092] The foam pieces resulting from granulation / shredding have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , optionally between 0.25 and 5 cm 3< , optionally between 0.25 and 2 cm 3< .

[0093] As regards the compression itself, it is performed such that the volume of the foam when compressed corresponds to 70 to 95 % of the total volume of the foam before compression, i.e., when no compression was applied and prior to compression. Such percentage may specifically be within the range of 75 to 85 %.

[0094] The compression may be maintained during 300 to 2,200 hours, optionally 720 to 1,440 hours. I.e., the compression within the above-mentioned range of the volume of the foam prior to compression may be maintained during a period within the above-mentioned range. The foam is thus compressed and stored for at least 300 hours to allow a change of the properties of the foam. Only then a foam compressed block is ready to proceed with granulation / shredding.

[0095] Subsequently, and whichever is the alternative of the first step, the foam pieces are agglomerated by means of bonding with a binding agent. The binding agent is provided in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25%. The remainder of the agglomerated foam layer may be formed entirely by the foam pieces or by the foam pieces and an additive.

[0096] In a first alternative, an agglomerated foam layer is thereby obtained. Such alternative may be obtained, for instance, by performing agglomeration within a mould corresponding to the desired layer.

[0097] In a second alternative, an agglomerated foam block may be obtained and subsequently cut to obtain a foam layer for a mattress. Such alternative may be obtained, for instance, by performing agglomeration within a mould corresponding to the desired block, wherein such block is subsequently cut.

[0098] In the first alternative, the mould may be such that the resulting thickness is of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0099] In the second alternative, the block may be cut such that the resulting thickness is within the ranges of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0100] Reference is made to the method of producing a mattress.

[0101] Such method includes previously performing the method of producing an agglomerated foam layer of the present disclosure to obtain an agglomerated foam layer which is differentiated and allows to obtain the advantages of the present disclosure.

[0102] Two enveloping layers are then provided to envelop the agglomerated foam layer. Each enveloping layer comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

[0103] A standard foam enveloping layer may have a density of 20-40 kg.m -3< or 25-30 kg.m -3< , and may have a thickness of 15-45 mm or 25-30 mm. A high resilience foam enveloping layer may have a density of 20-40 kg.m -3< or 25-30 kg.m -3< , and may have a thickness of 15-85 mm, 15-90 mm, 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, or 20 mm or 30 mm or 35 mm or 65 mm or 75 mm. The memory foam enveloping layer may have a density of 30-100 kg.m -3< or of 40-70 kg.m -3< .

[0104] The agglomerated foam layer is then provided between the two enveloping layers, i.e., the two enveloping layers are provided above and below the agglomerated foam layer. The process may then include providing a first enveloping layer, then providing the agglomerated foam layer on top of the first enveloping layer, and then providing a second enveloping layer on top of the agglomerated foam layer.

[0105] The method may include providing additional layers. For instance, providing a spring portion between two layers, for instance two standard foam layers. The spring portion is a pocket spring portion, the method comprising forming an enclosure of the pocket springs of agglomerated foam. The agglomerated foam may be an agglomerated foam layer within the terms of the present disclosure or an agglomerated foam obtained as known in the art.

[0106] More than one inner layer may be obtained, i.e., more than one layer which consists of an agglomerated foam layer according to the present disclosure. Each of such layers is provided between two enveloping layers.

[0107] For instance, a first enveloping layer may be provided. A first inner or first agglomerated foam layer is then provided on top of the first enveloping layer. A second enveloping layer is then provided on top of the fist agglomerated foam layer. A second agglomerated foam layer is then provided on top of the second enveloping layer. Finally, a third enveloping layer is provided on top of the second agglomerated foam layer.

[0108] The method may include providing an inner layer formed as a mixed inner layer, i.e. comprising one or more agglomerated foam portions and one or more standard foam portions.

[0109] Such specifics may include bonding several portions of agglomerated foam and standard foam in parallel, along the direction of arrangement of a layer. This direction may be regarded as horizontally, considering the arrangement of a mattress. The agglomerated foam portions are obtained according to the present disclosure. Thus, the mixed inner layer may be formed by means of two agglomerated foam portions and three standard foam portions, the agglomerated foam portions alternating with the standard foam portions along one of the length or the width of the layer.

[0110] The method of producing a mattress may be such that a first layer is formed with portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, is formed with portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0111] Thus, an agglomerated foam layer with portions with different thicknesses may be obtained by cutting an agglomerated foam layer which has a parallelepiped form. It may alternatively be obtained by means of a mould used for bonding / agglomerating which has such form with different thicknesses.

[0112] Further layers may be provided above or below the inner layer and the enveloping layers in the set of layers, for instance composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam as previously described. In a process of production, a further layer is provided in its respective sequence of positioning, on top of a previously arranged layer.

[0113] Upon provision of all the layers, the total thickness of the mattress may be within the range of 15-35 cm, the total length of the mattress may be within the range of 90-250 cm, 180-210 cm, 190 or 200 cm and the total width of the mattress is of 50-240 cm, 60-210 cm, 70-200 cm, 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, or 200 cm.

[0114] One of the enveloping layers may be a non-woven fabric sheet layer. Such non-woven fabric sheet layer may, as previously described, be provided before the agglomerated foam layer, i.e., the non-woven fabric sheet layer is arranged, and the agglomerated foam layer is provided on top of it. A second enveloping layer, be it a non-woven fabric sheet layer or not, is then provided on top of the agglomerated foam layer. In addition, the non-woven fabric sheet layer may be associated with, adjacently provided to, one layer formed of springs as previously described. The spring layer is then arranged prior to the arrangement of the non-woven fabric sheet layer. Thus, the non-woven fabric sheet layer is provided on top of the spring layer.

[0115] Reference is made to the method of packaging a mattress.

[0116] The method includes providing a mattress according to the present disclosure or, conversely, performing the method of producing a mattress of the present disclosure.

[0117] The mattress thereby obtained, which contains an agglomerated foam layer according to the present disclosure, is then to be rolled, to be folded, or to be folded and rolled. The method thereby includes mechanically stressing the mattress in order to reduce the volume it occupies.

[0118] In addition, the mattress may be enveloped in a plastic clover, such that it may be kept in the rolled, folded or folded and rolled format, in reduced volume. In addition, and to further facilitate keeping the mattress in such format, a vacuum may be provided within the plastic cover.

[0119] For instance, the method of packaging a mattress may include providing a plastic cover around the mattress, obtaining a plastic covered mattress, removing air from inside the plastic cover, thus providing a vacuum within the plastic cover, thereby reducing the volume of the mattress and obtaining a vacuum plastic covered mattress, then folding the vacuum plastic covered mattress along a first direction, e.g. along its length (half length) or width (half width), obtaining a folded mattress, and then rolling the folded mattress along a second direction, e.g. along its width if the first direction was length or along its length if the first direction was width. EXAMPLES AND RESULTS

[0120] Five non-limiting examples of agglomerated foam layers, two of which are according to the present disclosure, are subsequently presented.

[0121] The five agglomerated foam layers were obtained through the same process of agglomeration, except in that Examples A4 and A5 were obtained with foam which was compressed prior to agglomeration according to the present disclosure (pre-compression).

[0122] Some of the examples were packaged. All were packaged according to the same procedure. The packaging procedure included, after obtaining a mattress, providing a plastic cover was provided around it, forming vacuum within it, folding along a first direction (length or width) and then rolling along a second direction (length in case first direction was width or width in case first direction was length).

[0123] Examples A1, A2 and A4 were packaged. They were then kept in such format for 48 days (1,152 hours). Examples A3 and A5 remained in flat format. Table 1 - Features of Examples A1-A5Pre-compressionPackagingExample A1 (A1)NoYesExample A2 (A2)NoYesExample A3 (A3)NoNo (flat)Example A4 (A4)YesYesExample A5 (A5)YesNo (flat)

[0124] The thickness of each of the mattresses was measured prior to packaging along its length [values (1)] and the average value was obtained [T Avg. (2)].

[0125] After being maintained in the packaging during the 48 days, Examples 1, 2 and 4 were released / opened. The thickness of each of the mattresses was thus measured after packaging along its length [values (2)] and the average value was obtained [T Avg. (2)]. The results are presented in Table 2. Table 2 - variation of thickness along the mattresses prior to packaging and after packagingThickness prior to packaging (1) (mm)Thickness after packaging (2) (mm)T1(1)T2(1)T3(1)T4(1)T Avg. (1)T1(2)T2(2)T3(2)T4(2)T Avg. (2)A1150152151149151140125153112133A2147151152149150130105139108121A3150145148145147NANANANANAA4152154153151153149154154150152A5155150150154152NANANANANA

[0126] It can be seen that, prior to packaging, the variation of thickness along the length of the mattress is substantially negligible for any of the examples A1-A5. Yet, after packaging Examples A1 and A2 show a high deviation in some of the lengths when compared to the average and to other lengths. For instance, for A1 the thickness at T4 is 21 mm lower than the average and 31 mm lower than the thickness at T3. For A2, the thickness at T4 is 13 mm lower than the average and 31 mm lower than the thickness at T3.

[0127] Contrarily, in A4 the thickness after packaging remains unchanged, wherein the measured variation is within a margin of error. Table 3 presents the variation of the average thickness after packaging, in Examples A1, A2 and A4.

[0128] Even though A1 and A2 examples show similar results, such similarity outcomes from the variability of the material. The pre-compression as performed within the terms of the present disclosure reduces such variability, allowing that any sample of the used material shows desirable results. Table 3 - variation of thickness after packagingThickness variation abs. (mm)Thickness variation %Example A1-18-12 %Example A2-29-20 %Example A3NANAExample A4-1-1 %Example A5NANA

[0129] Thus, non-pre-compressed agglomerated layers show a high variation in thickness, between 12 and 20 %, a very significant value, which renders an associated mattress as an inferior solution.

[0130] The thickness and the hardness after packaging was measured for Examples A1 to A5 at 100 cycles (T0) after packaging and at 30,000 cycles (T1) after packaging.

[0131] Thickness and hardness were measured according to EN 1957:2012, particularly as it specifies measurement points T0 and T1 for assessing mattress hardness.

[0132] The standard EN 1957:2012 outlines a methodology for evaluating functional characteristics and durability of mattresses, including specific measurement points denoted as T0 and T1.

[0133] T0 represents the initial hardness measurement of the mattress prior to any durability testing, while T1 corresponds to the hardness measurement obtained after the durability testing process. This durability testing involves the repeated application of a compression roller over the mattress surface, simulating long-term use. Hardness and thickness values at T0 and T1 can then be compared to assess the performance of a mattress - or of a layer of a mattress, in the present case. Table 4 - variation of hardness and thickness upon 100 cycles (T0) and 30,000 cycles (T1)Thickness variation T0-T1 (mm)Thickness variation T0-T1 %Hardness variation T0-T1 abs. (N / mm)Hardness variation T0-T1 %Example A1-9.7-8.5 %3.1-30.4 %Example A2-4.8-4.7 %4.5-44.4 %Example A3-4.2-3.3 %-1.512.9 %Example A4-3,6-2.6 %1.1-6.9 %Example A5-1.6-1.2 %-0.85.6 %

[0134] The compression roller test specified in EN 1957:2012 subjects the mattress to a predefined number of cycles, wherein point T0 of measurement refers to 100 roller cycles and point T0 of measurement refers to 30,000 roller cycles. Examples A1 to A5 were tested according to such methodology, after packaging. Table 4 presents the variation in such values for each of the examples.

[0135] The results of Table 4 highlight the significant changes in the examples which were not pre-compressed, particularly A1, A2 and A3. The thickness variation in Examples A1 to A3 was always above a 3.3 % reduction, i.e. more than 4 mm, and applicable to A3, which was not packaged. A1 and A2 showed reductions in the range of 5 % or higher. Moreover, the variation in hardness was very significant in Examples A1 and A2, ranging from 30 % or more.

[0136] These results show a complete unsuitability of agglomerated foam layers as known in the art in comfort mattresses which are packaged, both after packaging and during the usage of a corresponding mattress, leading to high thickness variations. In addition, they also show an unacceptable decrease in hardness during the usage of a corresponding mattress. Moreover, and although in a lesser degree and results, comfort mattresses having agglomerated foam layers known in the art and which are maintained flat still show significant variations during usage, leading to inferior solutions.

[0137] Only examples A4 and A5, which consist of agglomerated foam layers according to the present disclosure, show reduced variations in all indicators: thickness variation upon packaging, thickness variation during usage and hardness variation during usage.

[0138] Now turning to mattresses according to the present disclosure, several non-limiting examples of the mattress of the present disclosure are subsequently presented.

[0139] Example M1 consists of a mattress (100) having the following layers: a memory foam layer (a further layer) (30), a normal high resilience layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a non-woven fabric sheet layer (an enveloping layer) (20), a set of pocket springs having five zones and enclosed within an agglomerated foam box (forming an inner layer, the inner layer provided above operating as a lid for such box) (10), a non-woven fabric sheet layer (an enveloping layer) (20), another layer having agglomerated foam (an inner layer) (10), a standard normal foam layer (a further layer) (30).

[0140] Example M2 consists of a mattress (100) having the following layers, in the following order from top to bottom: a memory foam layer (a further layer) (30), a hipersoft foam layer (a further layer) (30), a normal high resilience layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a standard normal foam layer (an enveloping layer) (20).

[0141] Example M3 consists of a mattress (100) having the following layers, in the following order from top to bottom: hipersoft foam layer (a further layer) (30), a normal high resilience layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a standard normal foam layer (an enveloping layer) (20), a normal high resilience layer (a further layer) (30).

[0142] Example M4 consists of a mattress (100) having the following layers, in the following order from top to bottom: a phase change material composite foam layer (an enveloping layer) (20), an agglomerated foam and standard foam layer (a mixed inner layer) (11), an agglomerated foam layer (an inner layer) (10), a non-woven fabric sheet layer (an enveloping layer) (20), a set of edge-to-edge pocket springs having a TNT sheet provided on top and a TNT sheet provided below the springs (a composed spring layer) (40), a non-woven fabric sheet layer (a further layer) (20), a standard normal foam layer (a further layer) (30).

[0143] Example M5 consists of a mattress (100) having the following layers, in the following order from top to bottom: a normal high resilience layer foam layer (an enveloping layer) (20), an agglomerated foam and standard foam layer (a mixed inner layer) (11), another normal high resilience foam layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a standard normal foam layer (an enveloping layer) (20).

[0144] In all the examples, the set of layers is completely covered with stretch fabric (e.g. GRS). Table 5 presents the density of each of the layers of each of the Examples M1-M5.Table 5 - density of each layer of five examplesdensityM1M2M3M4M5Memory foam6560---Hipersoft foam-383838-Normal HR foam303030-30Agglomerated foam505050--2x Agglomerated + 3x standard foam---50 + 3550 + 285zones pocket springs250 / m2----Normal HR foam----30Agglomerated foam50--5050E2E pocket springs--- / -standard normal foam2828282828Normal HR foam--30-- Table 6 presents the thickness (full thickness of the layer) of each of the layers of each of the Examples 1-5. Table 6 - thickness of each layer of the five examplesheightM1M2M3M4M5Memory foam3020---Hipersoft foam-203020-Normal HR foam307565-20Agglomerated foam27125110--2x reb + 3x standard foam---27635zones pocket springs120----Normal HR foam----45Agglomerated foam27--2763E2E pocket springs---150-standard normal foam2020402020Normal HR foam--35--

[0145] As will be clear to one skilled in the art, the present disclosure should not be limited to the particulars described herein, and a number of changes are possible while remaining within the terms of the present disclosure and appended claims.

[0146] Of course, the particulars disclosed herein are combinable, in the different possible forms, being avoided the repetition of all such combinations.

Examples

first embodiment

[0088]Alternatively, compressing foam to obtain compressed foam pieces may include providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces. Such alternative provides a more even material, as the compression stress is better provided to all of the compressed whole assembly, when compared to the compression of a foam pieces assembly. The foam portion is a whole foam portion, contrarily to the first embodiment, in which the foam is already granulated.

[0089]Whichever is the case, the foam used to obtain the agglomerated foam layer has a density of 15-60 kg.m -3< , 40-60 kg.m -3< , 45-55 kg.m -3< , 46-54 kg.m -3< , 47-53 kg.m -3< , 48-52 kg.m -3< , 49-51 kg.m -3< , or 50 kg.m -3< . Thus, either the foam portion or the pieces of the ensemble of shredded or granulated foam pieces have a density within such range.

[0090]In the case of the ...

example a1 (

Example A1 (A1)NoYes

example a2 (

Example A2 (A2)NoYes

TECHNICAL AREA

[0001] The present disclosure is within the technical area of layers of foam for mattresses and mattresses formed of a plurality of layers, for a person to lay on and rest, typically being provided on a bed.PRIOR ART

[0002] Mattresses are a type of product which, although seemingly consisting of a single piece, are composed of multiple elements.

[0003] Particularly, mattresses made of several layers not only are composed of such several layers as they may also comprise springs and corresponding enclosures, as well as covering materials such as stretch fabric.

[0004] The ability to assemble and disassemble the mattresses into and from several elements is, thus a challenge. Mattresses known in the art require the production of layers from raw materials and / or fail in the ability to disassemble again into the several elements, for subsequent recycling.

[0005] The solution of the present disclosure provides a layer for a mattress and a mattress which include recycled elements and which enable eased production and transport.

[0006] Agglomerated foam is known in prior art in association with mattresses that are too firm and uncomfortable, composed of surplus foams without selection and without concern for comfort, and of very high hardness and density.

[0007] Moreover, intense and / or prolonged compression of agglomerated foams causes some cells to collapse, resulting in plastic or permanent deformation. In this way, mattresses known in the art having agglomerated foam layers and that are rolled or folded and rolled have a time limit for being kept rolled in order to avoid plastic or permanent deformation. Within that period, the foams lose some of their physical properties, both in terms of cellular structure and foam hardness, as well as volume. Typically, this condition leads to such mattresses being produced and transported only in flat format.

[0008] These changes are even more significant in low-density and low-quality foams, commonly present in agglomerated foams, as they have greater fragility in their cell walls.

[0009] The solution of the present disclosure overcomes such issues, by providing an agglomerated foam layer suitable for comfort mattress solutions and which, when provided in a mattress, allows such mattress to be rolled or folded.SUMMARY OF THE DISCLOSURE

[0010] The present disclosure includes an agglomerated foam layer for a mattress. The layer comprises foam pieces and a binding agent, wherein prior to agglomeration the foam has been subjected to compression to a volume corresponding to 65 to 95 % of its total volume before compression.

[0011] The said compression may have been performed to a volume corresponding 70 to 95 % of the total volume of the foam before compression, optionally 75 to 85 %.

[0012] The compression may have been maintained during 300 to 2,200 hours, optionally 720 to 1,440 hours.

[0013] The pieces of foam may have a density of 15-60 kg.m -3< , optionally a density of 40-60 kg.m -3< , optionally a density of 45-55 kg.m -3< , optionally a density of 46-54 kg.m -3< , optionally a density of 47-53 kg.m -3< , optionally a density of 48-52 kg.m -3< , optionally a density of 49-51 kg.m -3< , optionally a density of 50 kg.m -3< .

[0014] The thickness of the agglomerated foam layer may be within the range of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0015] The pieces of foam are polyurethane and / or polyurethane repolyol foam pieces.

[0016] The binding agent may be present in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25%.

[0017] The foam pieces may have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , optionally between 0.25 and 5 cm 3< , optionally between 0.25 and 2 cm 3< .

[0018] The present disclosure may further comprise a mattress comprising a plurality of layers. The plurality of layers may include an inner layer comprising the agglomerated foam layer of the present disclosure and at least two enveloping layers, the agglomerated layer being provided between the two enveloping layers, wherein each of the enveloping layers comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

[0019] For each enveloping layer, the enveloping layer may have when composed of a standard foam, a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< , when composed of a high resilience foam, a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< .

[0020] For each enveloping layer, the enveloping layer may have when comprising a standard foam or being entirely composed of a standard foam, a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm.

[0021] The mattress may further comprise a spring portion provided between two layers.

[0022] The spring portion may be a pocket spring portion, and an enclosure of the pocket springs may be formed of agglomerated foam.

[0023] The mattress may comprise more than one inner layer, each inner layer being provided between two enveloping layers. A same enveloping layer may be a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress.

[0024] An inner layer may be a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions.

[0025] The mixed inner layer may comprise two agglomerated foam portions and three standard foam portions, the agglomerated foam portions alternating with the standard foam portions along one of the length or the width of the layer.

[0026] A first layer may have portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, may also have portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0027] The mattress may comprise further layers provided above or below the inner layer and the enveloping layers in the set of layers, the further layers being composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam.

[0028] The total thickness of the mattress may be within the range of 15-35 cm.

[0029] The total length of the mattress may be within the range of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm.

[0030] The total width of the mattress may be within the range of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm.

[0031] One of the enveloping layers may be a non-woven fabric sheet layer, the mattress further comprising one layer formed of springs adjacently provided to the non-woven fabric sheet layer and forming a composed spring layer with non-woven fabric sheet layer.

[0032] The present disclosure further comprises the use of the agglomerated foam layer of the present disclosure as a layer in a mattress.

[0033] The present disclosure may further comprise the use of the mattress of the present disclosure rolled, folded or folded and rolled and packaged in vacuum within a plastic cover.

[0034] The present disclosure may further comprise a method of producing an agglomerated foam layer for a mattress, the method comprising compressing foam to obtain compressed foam pieces by providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression, or providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces, agglomerating the foam pieces by means of bonding with a binding agent, and thereby obtaining an agglomerated foam layer or obtaining an agglomerated foam block and cutting such block to obtain a foam layer for a mattress.

[0035] The method of producing an agglomerated foam layer may be such that the compression is to a volume corresponding 70 to 95 % of the total volume of the foam before compression, optionally 75 to 85 %.

[0036] The method of producing an agglomerated foam layer may be such that the compression is performed during 300 to 2,200 hours, optionally 720 to 1,440 hours.

[0037] The method of producing an agglomerated foam layer may be such that the agglomerated foam comprises a plurality of pieces with a density of 15-60 kg.m -3< , optionally a density of 40-60 kg.m -3< , optionally a density of 45-55 kg.m -3< , optionally a density of 46-54 kg.m -3< , optionally a density of 47-53 kg.m -3< , optionally a density of 48-52 kg.m -3< , optionally a density of 49-51 kg.m -3< , optionally a density of 50 kg.m -3< .

[0038] The method of producing an agglomerated foam layer may be such that the resulting thickness is of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0039] The method of producing an agglomerated foam layer may be such that the pieces of foam are polyurethane and / or polyurethane repolyol foam pieces.

[0040] The method of producing an agglomerated foam layer may be such that in agglomeration the binding agent is provided in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25%.

[0041] The method of producing an agglomerated foam layer may be such that the foam pieces have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , optionally between 0.25 and 5 cm 3< , optionally between 0.25 and 2 cm 3< , optionally the method comprising shredding the foam portion to pieces having an average volume comprised between 0.15 and 25 cm 3< , and optionally between 0.5 and 5 cm 3< .

[0042] The present disclosure may further comprise a method of producing a mattress, the method comprising performing the method of producing an agglomerated foam layer of the present disclosure, thereby obtaining an agglomerated foam layer, providing two enveloping layers, each enveloping layer comprising a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet, providing the agglomerated foam layer between the two enveloping layers.

[0043] The method of producing a mattress may be such that, for each enveloping layer, when composed of a standard foam, has a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< , when composed of a high resilience foam, has a density of 20-40 kg.m -3< , optionally a density of 25-30 kg.m -3< .

[0044] The method of producing a mattress may be such that, for each enveloping layer, when comprising a standard foam or being entirely composed of a standard foam, has a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, has a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm.

[0045] The method of producing a mattress may be such that it further comprises providing a spring portion between two layers.

[0046] The method of producing a mattress may be such that the spring portion is a pocket spring portion, the method comprising forming an enclosure of the pocket springs of agglomerated foam.

[0047] The method of producing a mattress may be such that it comprises providing more than one inner layer, each inner layer being provided between two enveloping layers. A same enveloping layer may be a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress.

[0048] The method of producing a mattress may be such that an inner layer is provided as a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions.

[0049] The method of producing a mattress may be such that the mixed inner layer is formed by means of two agglomerated foam portions and three standard foam portions, the agglomerated foam portions alternating with the standard foam portions along one of the length or the width of the layer.

[0050] The method of producing a mattress may be such that a first layer is formed with portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, is formed with portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0051] The method of producing a mattress may be such that it comprises providing further layers above or below the inner layer and the enveloping layers in the set of layers, the further layers being composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam.

[0052] The method of producing a mattress may be such that the total thickness of the mattress is of 15-35 cm.

[0053] The method of producing a mattress may be such that the total length of the mattress is of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm.

[0054] The method of producing a mattress may be such that the total width of the mattress is of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm.

[0055] The method of producing a mattress may be such that one of the enveloping layers is a non-woven fabric sheet layer, the mattress further comprising one layer formed of springs adjacently provided to the non-woven fabric sheet layer and forming a composed spring layer with non-woven fabric sheet layer.

[0056] The present disclosure may further comprise a method of packaging a mattress, the method including, providing a mattress according to the present disclosure or performing the method of producing a mattress of the present disclosure, thereby obtaining a mattress, rolling, folding or folding and rolling the mattress, enveloping the rolled, folded or folded and rolled mattress in a plastic cover,

[0057] The method of packaging a mattress may further comprise providing a vacuum within the plastic covered rolled, folded or folded and rolled mattress.DESCRIPTION OF THE FIGURES

[0058] Figure 1 - A representation of a mattress according to example M1 of a mattress according to the present disclosure. Figure 2 - A representation of a mattress according to example M2 of a mattress according to the present disclosure. Figure 3 - A representation of a mattress according to example M3 of a mattress according to the present disclosure. Figure 4 - A representation of a mattress according to example M4 of a mattress according to the present disclosure. Figure 5 - A representation of a mattress according to example M5 of a mattress according to the present disclosure. DETAILED DESCRIPTION

[0059] The present disclosure includes an agglomerated foam layer for a mattress. The layer comprises foam pieces and a binding agent.

[0060] Agglomerated foam, also referred to as rebonded foam, is a composite material formed by combining shredded or granulated pieces of polyurethane foam with an adhesive binding agent. Such combination may be performed under compression.

[0061] The agglomerated foam layer thus is formed as a unitary assembly of the pieces of foam, bound by the binding agent.

[0062] Compression to a volume corresponding to 65 to 95 % (optionally to 70 to 95 % or 75 to 85 % of the total volume of the foam before compression) of its total volume before compression means that the ensemble that is compressed, be it a plurality of foam pieces or a whole portion of foam which is subsequently shredded of granulated, is compressed to a volume which corresponds to 65 to 95 % of the volume of such ensemble prior to being compression.

[0063] Such compression of the foam material, prior to agglomeration, allows that when forming a layer which is provided within a mattress, such mattress may be rolled or folded, resulting in no breakage of the agglomerated foam layer. The prior compression of the foam material which will then form an agglomerated foam removes the cellular fragilities of such foam surplus.

[0064] This process makes their characteristics more uniform, ensuring superior quality after the mattress in which such layer is provided is unrolled.

[0065] The compression is performed temporarily, being maintained during 300 to 2,200 hours or 720 to 1,440 hours, to provide an enhanced mattress.

[0066] The foam, prior to compression, may have a density within a range of 15-60 kg.m -3< , 40-60 kg.m -3< , 45-55 kg.m -3< , 46-54 kg.m -3< , 47-53 kg.m -3< , 48-52 kg.m -3< , 49-51 kg.m -3< , or 50 kg.m -3< . Thus, an agglomerated foam layer may comprise foam pieces such that, prior to compression, each of the pieces had a density within one of the said ranges. While consisting of foam surplus potentially from different sources, the density of each of the pieces may be different from the density of the other pieces.

[0067] The pieces of foam are polyurethane and / or polyurethane repolyol foam based pieces. Repolyol is a recycled polyol material derived from the chemical recycling of polyurethane (PU) foam sourced from foam production waste and end-of-life products, such as mattresses and upholstered furniture.

[0068] The foam pieces may have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , 0.25 and 5 cm 3< , or 0.25 and 2 cm 3< . An agglomerated foam layer may comprise agglomerated pieces such that, prior to compression, each of the pieces had a volume within one of the said ranges. While consisting of foam surplus potentially from different sources, the volume of each of the pieces may be different from the volume of the other pieces.

[0069] Reference is made to the mattress of the present disclosure. It comprises a plurality of layers which may include an inner layer comprising the agglomerated foam layer of the present disclosure and at least two enveloping layers, the agglomerated layer being provided between the two enveloping layers, wherein each of the enveloping layers comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

[0070] The standard foam has a density of 20-40 kg.m -3< or of 25-30 kg.m -3< . The high resilience foam has a density of 20-40 kg.m -3< or of 25-30 kg.m -3< . The memory foam has a density of 30-100 kg.m -3< or of 40-70 kg.m -3< .

[0071] Indentation Load Deflection (ILD) refers to the measurement of a force required to compress a specified area of a material, particularly a foam material, to a predetermined percentage of its original thickness. This parameter is expressed in units of force and serves as an indicator of the firmness or stiffness of a material.

[0072] The standardized testing procedure for measuring ILD, as outlined in ISO 2439:2008 Method B, is specifically designed for flexible cellular materials such as polyurethane foam. This method involves compressing a foam sample to 40% of its original thickness at a constant speed and for a specified hold time. The force required to achieve and maintain the specified 40% compression is measured and recorded, providing a consistent and reproducible assessment of the hardness characteristics of the material.

[0073] The standard foam is such that it has an ILD of 10-70 (lbs). The high resilience foam is such that it has an ILD of 15-50. The memory foam is such that it has an ILD of 10-25.

[0074] The thickness of enveloping layers may be adapted to the corresponding agglomerated foam layer and / or the desired characteristics of the mattress, including total thickness. Thickness may also be referred to as height, as it corresponds to the dimension which is typically vertically aligned. Each enveloping layer may have when comprising a standard foam or being entirely composed of a standard foam, a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm.

[0075] The mattress may further comprise a spring portion provided between two layers. The spring portion may be a pocket spring portion, and an enclosure of the pocket springs may be formed of agglomerated foam. The agglomerated foam may be obtained according to the method of the present disclosure, such that it comprises compressing foam to obtain compressed foam pieces by providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression, or providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces, agglomerating the foam pieces by means of bonding with a binding agent, and the agglomeration being such that an agglomerated foam enclosure for pocket springs is obtained by means of cutting the agglomerated foam block.

[0076] The mattress may comprise more than one inner layer, each inner layer being provided between two enveloping layers. A same enveloping layer may be a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress. Thus, three enveloping layers may envelop two inner layers, wherein one of the enveloping layers is shared by the two inner layers.

[0077] As is the case of the mattresses of Figures 4 and 5, an inner layer may be a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions. Each agglomerated foam portion and each standard foam portion may extend along the whole width of the mattress, wherein agglomerated foam portions and standard foam portions are intercalated.

[0078] A mixed inner layer may comprise two agglomerated foam portions and three standard foam portions, as is the case of the mattresses of Figures 4 and 5. The agglomerated foam portions alternating with the standard foam portions along one of the length or the width (case of Figures 4 and 5) of the layer.

[0079] As is the case with the mattresses of Figures 2 and 3, a first layer may have portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, may also have portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0080] The mattress may comprise further layers provided above or below the inner layer and the enveloping layers in the set of layers, the further layers being composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam.

[0081] The total thickness of the mattress, formed by the whole assembly of layers or the whole assembly of layers and a cover, for instance a stretch fabric cover, may be within the range of 15-35cm.

[0082] The total length of the mattress may be within the range of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm. Each layer has a length which corresponds to the length of the mattress.

[0083] The total width of the mattress may be within the range of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm. Each layer has a width which corresponds to the width of the mattress.

[0084] One of the enveloping layers may be a non-woven fabric sheet layer, the mattress further comprising one layer formed of springs adjacently provided to the non-woven fabric sheet layer and forming a composed spring layer with non-woven fabric sheet layer, as is the case of the mattresses of Figures 1 and 4.

[0085] Reference is made to the method of producing an agglomerated foam layer for a mattress of the present disclosure.

[0086] Two embodiments for obtaining compressed granulated foam pieces may be provided. Foam is polyurethane foam and / or polyurethane repolyol foam.

[0087] Compressing foam to obtain compressed foam pieces may include providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression.

[0088] Alternatively, compressing foam to obtain compressed foam pieces may include providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces. Such alternative provides a more even material, as the compression stress is better provided to all of the compressed whole assembly, when compared to the compression of a foam pieces assembly. The foam portion is a whole foam portion, contrarily to the first embodiment, in which the foam is already granulated.

[0089] Whichever is the case, the foam used to obtain the agglomerated foam layer has a density of 15-60 kg.m -3< , 40-60 kg.m -3< , 45-55 kg.m -3< , 46-54 kg.m -3< , 47-53 kg.m -3< , 48-52 kg.m -3< , 49-51 kg.m -3< , or 50 kg.m -3< . Thus, either the foam portion or the pieces of the ensemble of shredded or granulated foam pieces have a density within such range.

[0090] In the case of the ensemble of shredded or granulated foam pieces, and since they consist of foam surplus potentially from different sources, the density of each of the pieces may be different from the density of the other pieces. Thus, the method is such that a resulting agglomerated foam layer may comprise foam pieces such that, prior to compression, each of the pieces had a density within one of the said ranges.

[0091] In the case of the foam portion, it consists of a whole foam portion. Thus, the density of the foam portion is substantially the same along the whole foam portion, and is within the said ranges.

[0092] The foam pieces resulting from granulation / shredding have, before agglomeration, an average volume comprised between 0.15 and 30 cm 3< , optionally between 0.25 and 5 cm 3< , optionally between 0.25 and 2 cm 3< .

[0093] As regards the compression itself, it is performed such that the volume of the foam when compressed corresponds to 70 to 95 % of the total volume of the foam before compression, i.e., when no compression was applied and prior to compression. Such percentage may specifically be within the range of 75 to 85 %.

[0094] The compression may be maintained during 300 to 2,200 hours, optionally 720 to 1,440 hours. I.e., the compression within the above-mentioned range of the volume of the foam prior to compression may be maintained during a period within the above-mentioned range. The foam is thus compressed and stored for at least 300 hours to allow a change of the properties of the foam. Only then a foam compressed block is ready to proceed with granulation / shredding.

[0095] Subsequently, and whichever is the alternative of the first step, the foam pieces are agglomerated by means of bonding with a binding agent. The binding agent is provided in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25%. The remainder of the agglomerated foam layer may be formed entirely by the foam pieces or by the foam pieces and an additive.

[0096] In a first alternative, an agglomerated foam layer is thereby obtained. Such alternative may be obtained, for instance, by performing agglomeration within a mould corresponding to the desired layer.

[0097] In a second alternative, an agglomerated foam block may be obtained and subsequently cut to obtain a foam layer for a mattress. Such alternative may be obtained, for instance, by performing agglomeration within a mould corresponding to the desired block, wherein such block is subsequently cut.

[0098] In the first alternative, the mould may be such that the resulting thickness is of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0099] In the second alternative, the block may be cut such that the resulting thickness is within the ranges of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

[0100] Reference is made to the method of producing a mattress.

[0101] Such method includes previously performing the method of producing an agglomerated foam layer of the present disclosure to obtain an agglomerated foam layer which is differentiated and allows to obtain the advantages of the present disclosure.

[0102] Two enveloping layers are then provided to envelop the agglomerated foam layer. Each enveloping layer comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

[0103] A standard foam enveloping layer may have a density of 20-40 kg.m -3< or 25-30 kg.m -3< , and may have a thickness of 15-45 mm or 25-30 mm. A high resilience foam enveloping layer may have a density of 20-40 kg.m -3< or 25-30 kg.m -3< , and may have a thickness of 15-85 mm, 15-90 mm, 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, or 20 mm or 30 mm or 35 mm or 65 mm or 75 mm. The memory foam enveloping layer may have a density of 30-100 kg.m -3< or of 40-70 kg.m -3< .

[0104] The agglomerated foam layer is then provided between the two enveloping layers, i.e., the two enveloping layers are provided above and below the agglomerated foam layer. The process may then include providing a first enveloping layer, then providing the agglomerated foam layer on top of the first enveloping layer, and then providing a second enveloping layer on top of the agglomerated foam layer.

[0105] The method may include providing additional layers. For instance, providing a spring portion between two layers, for instance two standard foam layers. The spring portion is a pocket spring portion, the method comprising forming an enclosure of the pocket springs of agglomerated foam. The agglomerated foam may be an agglomerated foam layer within the terms of the present disclosure or an agglomerated foam obtained as known in the art.

[0106] More than one inner layer may be obtained, i.e., more than one layer which consists of an agglomerated foam layer according to the present disclosure. Each of such layers is provided between two enveloping layers.

[0107] For instance, a first enveloping layer may be provided. A first inner or first agglomerated foam layer is then provided on top of the first enveloping layer. A second enveloping layer is then provided on top of the fist agglomerated foam layer. A second agglomerated foam layer is then provided on top of the second enveloping layer. Finally, a third enveloping layer is provided on top of the second agglomerated foam layer.

[0108] The method may include providing an inner layer formed as a mixed inner layer, i.e. comprising one or more agglomerated foam portions and one or more standard foam portions.

[0109] Such specifics may include bonding several portions of agglomerated foam and standard foam in parallel, along the direction of arrangement of a layer. This direction may be regarded as horizontally, considering the arrangement of a mattress. The agglomerated foam portions are obtained according to the present disclosure. Thus, the mixed inner layer may be formed by means of two agglomerated foam portions and three standard foam portions, the agglomerated foam portions alternating with the standard foam portions along one of the length or the width of the layer.

[0110] The method of producing a mattress may be such that a first layer is formed with portions with different thicknesses, having a flat top side, and a second layer, adjacent to the first layer, is formed with portions with different thicknesses, having a flat bottom side, the first layer being provided above the second layer and fitting the second layer.

[0111] Thus, an agglomerated foam layer with portions with different thicknesses may be obtained by cutting an agglomerated foam layer which has a parallelepiped form. It may alternatively be obtained by means of a mould used for bonding / agglomerating which has such form with different thicknesses.

[0112] Further layers may be provided above or below the inner layer and the enveloping layers in the set of layers, for instance composed of a memory foam, a memory foam with a phase-change material coolgraph coating, a hipersoft foam, a normal high resilience foam, a standard foam, or an agglomerated foam as previously described. In a process of production, a further layer is provided in its respective sequence of positioning, on top of a previously arranged layer.

[0113] Upon provision of all the layers, the total thickness of the mattress may be within the range of 15-35 cm, the total length of the mattress may be within the range of 90-250 cm, 180-210 cm, 190 or 200 cm and the total width of the mattress is of 50-240 cm, 60-210 cm, 70-200 cm, 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, or 200 cm.

[0114] One of the enveloping layers may be a non-woven fabric sheet layer. Such non-woven fabric sheet layer may, as previously described, be provided before the agglomerated foam layer, i.e., the non-woven fabric sheet layer is arranged, and the agglomerated foam layer is provided on top of it. A second enveloping layer, be it a non-woven fabric sheet layer or not, is then provided on top of the agglomerated foam layer. In addition, the non-woven fabric sheet layer may be associated with, adjacently provided to, one layer formed of springs as previously described. The spring layer is then arranged prior to the arrangement of the non-woven fabric sheet layer. Thus, the non-woven fabric sheet layer is provided on top of the spring layer.

[0115] Reference is made to the method of packaging a mattress.

[0116] The method includes providing a mattress according to the present disclosure or, conversely, performing the method of producing a mattress of the present disclosure.

[0117] The mattress thereby obtained, which contains an agglomerated foam layer according to the present disclosure, is then to be rolled, to be folded, or to be folded and rolled. The method thereby includes mechanically stressing the mattress in order to reduce the volume it occupies.

[0118] In addition, the mattress may be enveloped in a plastic clover, such that it may be kept in the rolled, folded or folded and rolled format, in reduced volume. In addition, and to further facilitate keeping the mattress in such format, a vacuum may be provided within the plastic cover.

[0119] For instance, the method of packaging a mattress may include providing a plastic cover around the mattress, obtaining a plastic covered mattress, removing air from inside the plastic cover, thus providing a vacuum within the plastic cover, thereby reducing the volume of the mattress and obtaining a vacuum plastic covered mattress, then folding the vacuum plastic covered mattress along a first direction, e.g. along its length (half length) or width (half width), obtaining a folded mattress, and then rolling the folded mattress along a second direction, e.g. along its width if the first direction was length or along its length if the first direction was width. EXAMPLES AND RESULTS

[0120] Five non-limiting examples of agglomerated foam layers, two of which are according to the present disclosure, are subsequently presented.

[0121] The five agglomerated foam layers were obtained through the same process of agglomeration, except in that Examples A4 and A5 were obtained with foam which was compressed prior to agglomeration according to the present disclosure (pre-compression).

[0122] Some of the examples were packaged. All were packaged according to the same procedure. The packaging procedure included, after obtaining a mattress, providing a plastic cover was provided around it, forming vacuum within it, folding along a first direction (length or width) and then rolling along a second direction (length in case first direction was width or width in case first direction was length).

[0123] Examples A1, A2 and A4 were packaged. They were then kept in such format for 48 days (1,152 hours). Examples A3 and A5 remained in flat format. Table 1 - Features of Examples A1-A5Pre-compressionPackagingExample A1 (A1)NoYesExample A2 (A2)NoYesExample A3 (A3)NoNo (flat)Example A4 (A4)YesYesExample A5 (A5)YesNo (flat)

[0124] The thickness of each of the mattresses was measured prior to packaging along its length [values (1)] and the average value was obtained [T Avg. (2)].

[0125] After being maintained in the packaging during the 48 days, Examples 1, 2 and 4 were released / opened. The thickness of each of the mattresses was thus measured after packaging along its length [values (2)] and the average value was obtained [T Avg. (2)]. The results are presented in Table 2. Table 2 - variation of thickness along the mattresses prior to packaging and after packagingThickness prior to packaging (1) (mm)Thickness after packaging (2) (mm)T1(1)T2(1)T3(1)T4(1)T Avg. (1)T1(2)T2(2)T3(2)T4(2)T Avg. (2)A1150152151149151140125153112133A2147151152149150130105139108121A3150145148145147NANANANANAA4152154153151153149154154150152A5155150150154152NANANANANA

[0126] It can be seen that, prior to packaging, the variation of thickness along the length of the mattress is substantially negligible for any of the examples A1-A5. Yet, after packaging Examples A1 and A2 show a high deviation in some of the lengths when compared to the average and to other lengths. For instance, for A1 the thickness at T4 is 21 mm lower than the average and 31 mm lower than the thickness at T3. For A2, the thickness at T4 is 13 mm lower than the average and 31 mm lower than the thickness at T3.

[0127] Contrarily, in A4 the thickness after packaging remains unchanged, wherein the measured variation is within a margin of error. Table 3 presents the variation of the average thickness after packaging, in Examples A1, A2 and A4.

[0128] Even though A1 and A2 examples show similar results, such similarity outcomes from the variability of the material. The pre-compression as performed within the terms of the present disclosure reduces such variability, allowing that any sample of the used material shows desirable results. Table 3 - variation of thickness after packagingThickness variation abs. (mm)Thickness variation %Example A1-18-12 %Example A2-29-20 %Example A3NANAExample A4-1-1 %Example A5NANA

[0129] Thus, non-pre-compressed agglomerated layers show a high variation in thickness, between 12 and 20 %, a very significant value, which renders an associated mattress as an inferior solution.

[0130] The thickness and the hardness after packaging was measured for Examples A1 to A5 at 100 cycles (T0) after packaging and at 30,000 cycles (T1) after packaging.

[0131] Thickness and hardness were measured according to EN 1957:2012, particularly as it specifies measurement points T0 and T1 for assessing mattress hardness.

[0132] The standard EN 1957:2012 outlines a methodology for evaluating functional characteristics and durability of mattresses, including specific measurement points denoted as T0 and T1.

[0133] T0 represents the initial hardness measurement of the mattress prior to any durability testing, while T1 corresponds to the hardness measurement obtained after the durability testing process. This durability testing involves the repeated application of a compression roller over the mattress surface, simulating long-term use. Hardness and thickness values at T0 and T1 can then be compared to assess the performance of a mattress - or of a layer of a mattress, in the present case. Table 4 - variation of hardness and thickness upon 100 cycles (T0) and 30,000 cycles (T1)Thickness variation T0-T1 (mm)Thickness variation T0-T1 %Hardness variation T0-T1 abs. (N / mm)Hardness variation T0-T1 %Example A1-9.7-8.5 %3.1-30.4 %Example A2-4.8-4.7 %4.5-44.4 %Example A3-4.2-3.3 %-1.512.9 %Example A4-3,6-2.6 %1.1-6.9 %Example A5-1.6-1.2 %-0.85.6 %

[0134] The compression roller test specified in EN 1957:2012 subjects the mattress to a predefined number of cycles, wherein point T0 of measurement refers to 100 roller cycles and point T0 of measurement refers to 30,000 roller cycles. Examples A1 to A5 were tested according to such methodology, after packaging. Table 4 presents the variation in such values for each of the examples.

[0135] The results of Table 4 highlight the significant changes in the examples which were not pre-compressed, particularly A1, A2 and A3. The thickness variation in Examples A1 to A3 was always above a 3.3 % reduction, i.e. more than 4 mm, and applicable to A3, which was not packaged. A1 and A2 showed reductions in the range of 5 % or higher. Moreover, the variation in hardness was very significant in Examples A1 and A2, ranging from 30 % or more.

[0136] These results show a complete unsuitability of agglomerated foam layers as known in the art in comfort mattresses which are packaged, both after packaging and during the usage of a corresponding mattress, leading to high thickness variations. In addition, they also show an unacceptable decrease in hardness during the usage of a corresponding mattress. Moreover, and although in a lesser degree and results, comfort mattresses having agglomerated foam layers known in the art and which are maintained flat still show significant variations during usage, leading to inferior solutions.

[0137] Only examples A4 and A5, which consist of agglomerated foam layers according to the present disclosure, show reduced variations in all indicators: thickness variation upon packaging, thickness variation during usage and hardness variation during usage.

[0138] Now turning to mattresses according to the present disclosure, several non-limiting examples of the mattress of the present disclosure are subsequently presented.

[0139] Example M1 consists of a mattress (100) having the following layers: a memory foam layer (a further layer) (30), a normal high resilience layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a non-woven fabric sheet layer (an enveloping layer) (20), a set of pocket springs having five zones and enclosed within an agglomerated foam box (forming an inner layer, the inner layer provided above operating as a lid for such box) (10), a non-woven fabric sheet layer (an enveloping layer) (20), another layer having agglomerated foam (an inner layer) (10), a standard normal foam layer (a further layer) (30).

[0140] Example M2 consists of a mattress (100) having the following layers, in the following order from top to bottom: a memory foam layer (a further layer) (30), a hipersoft foam layer (a further layer) (30), a normal high resilience layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a standard normal foam layer (an enveloping layer) (20).

[0141] Example M3 consists of a mattress (100) having the following layers, in the following order from top to bottom: hipersoft foam layer (a further layer) (30), a normal high resilience layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a standard normal foam layer (an enveloping layer) (20), a normal high resilience layer (a further layer) (30).

[0142] Example M4 consists of a mattress (100) having the following layers, in the following order from top to bottom: a phase change material composite foam layer (an enveloping layer) (20), an agglomerated foam and standard foam layer (a mixed inner layer) (11), an agglomerated foam layer (an inner layer) (10), a non-woven fabric sheet layer (an enveloping layer) (20), a set of edge-to-edge pocket springs having a TNT sheet provided on top and a TNT sheet provided below the springs (a composed spring layer) (40), a non-woven fabric sheet layer (a further layer) (20), a standard normal foam layer (a further layer) (30).

[0143] Example M5 consists of a mattress (100) having the following layers, in the following order from top to bottom: a normal high resilience layer foam layer (an enveloping layer) (20), an agglomerated foam and standard foam layer (a mixed inner layer) (11), another normal high resilience foam layer (an enveloping layer) (20), an agglomerated foam layer (an inner layer) (10), a standard normal foam layer (an enveloping layer) (20).

[0144] In all the examples, the set of layers is completely covered with stretch fabric (e.g. GRS). Table 5 presents the density of each of the layers of each of the Examples M1-M5.Table 5 - density of each layer of five examplesdensityM1M2M3M4M5Memory foam6560---Hipersoft foam-383838-Normal HR foam303030-30Agglomerated foam505050--2x Agglomerated + 3x standard foam---50 + 3550 + 285zones pocket springs250 / m2----Normal HR foam----30Agglomerated foam50--5050E2E pocket springs--- / -standard normal foam2828282828Normal HR foam--30-- Table 6 presents the thickness (full thickness of the layer) of each of the layers of each of the Examples 1-5. Table 6 - thickness of each layer of the five examplesheightM1M2M3M4M5Memory foam3020---Hipersoft foam-203020-Normal HR foam307565-20Agglomerated foam27125110--2x reb + 3x standard foam---27635zones pocket springs120----Normal HR foam----45Agglomerated foam27--2763E2E pocket springs---150-standard normal foam2020402020Normal HR foam--35--

[0145] As will be clear to one skilled in the art, the present disclosure should not be limited to the particulars described herein, and a number of changes are possible while remaining within the terms of the present disclosure and appended claims.

[0146] Of course, the particulars disclosed herein are combinable, in the different possible forms, being avoided the repetition of all such combinations.

Examples

first embodiment

[0088]Alternatively, compressing foam to obtain compressed foam pieces may include providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces. Such alternative provides a more even material, as the compression stress is better provided to all of the compressed whole assembly, when compared to the compression of a foam pieces assembly. The foam portion is a whole foam portion, contrarily to the first embodiment, in which the foam is already granulated.

[0089]Whichever is the case, the foam used to obtain the agglomerated foam layer has a density of 15-60 kg.m -3< , 40-60 kg.m -3< , 45-55 kg.m -3< , 46-54 kg.m -3< , 47-53 kg.m -3< , 48-52 kg.m -3< , 49-51 kg.m -3< , or 50 kg.m -3< . Thus, either the foam portion or the pieces of the ensemble of shredded or granulated foam pieces have a density within such range.

[0090]In the case of the ...

example a1 (

Example A1 (A1)NoYes

example a2 (

Example A2 (A2)NoYes

Claims

1. An agglomerated foam layer for a mattress, the layer comprising foam pieces and a binding agent, wherein prior to agglomeration the foam has been subjected to compression to a volume corresponding to 65 to 95 % of its total volume before compression.

2. An agglomerated foam layer according to the previous claim wherein the compression was performed to a volume corresponding 70 to 95 % of the total volume of the foam before compression, optionally 75 to 85 %.

3. An agglomerated foam layer according to any of the preceding claims wherein the compression was maintained during 300 to 2,200 hours, optionally 720 to 1,440 hours.

4. An agglomerated foam layer according to any of the preceding claims wherein pieces of foam with a density of 15-60 kg.m-3, optionally a density of 40-60 kg.m-3, optionally a density of 45-55 kg.m-3, optionally a density of 46-54 kg.m-3, optionally a density of 47-53 kg.m-3, optionally a density of 48-52 kg.m-3, optionally a density of 49-51 kg.m-3, optionally a density of 50 kg.m-3, and or the agglomerated foam layer having a thickness of 20-130 mm, optionally 20-40 mm or 55-70 mm or 105-130 mm, optionally 20-25 mm, 60-65 mm or 105-115 mm or 120-130 mm, optionally 27, 63, 110 or 125 mm.

5. An agglomerated foam layer according to any of the preceding claims wherein the pieces of foam are polyurethane and / or polyurethane repolyol foam pieces.

6. An agglomerated foam layer according to any of the preceding claims wherein the binding agent is present in 5 to 35% of the total mass of the foam layer, optionally between 10 and 25% and, optionally, the foam pieces have, before agglomeration, an average volume comprised between 0.15 and 30 cm3, optionally between 0.25 and 5 cm3, optionally between 0.25 and 2 cm3.

7. A mattress comprising a plurality of layers, the plurality of layers including an inner layer comprising the agglomerated foam layer of any of the preceding claims and at least two enveloping layers, the agglomerated layer being provided between the two enveloping layers, wherein each of the enveloping layers comprises a standard foam, a high resilience foam, a memory foam or a non-woven fabric sheet.

8. A mattress according to the previous claim wherein, for each enveloping layer, when composed of a standard foam, has a density of 20-40 kg.m-3, optionally a density of 25-30 kg.m-3, when composed of a high resilience foam, has a density of 20-40 kg.m-3, optionally a density of 25-30 kg.m-3.

9. A mattress according to any of the claims 7-8 wherein, for each enveloping layer, when comprising a standard foam or being entirely composed of a standard foam, has a thickness of 15-45 mm, optionally of 25-30 mm, when comprising a high resilience foam or being entirely composed of a high resilience foam, has a thickness of 15-85 mm, optionally of 15-90 mm, optionally 15-25 mm or 25-35 mm or 30-40 mm or 35-45 mm or 45-55 mm or 55-65 mm or 65-75 mm or 75-85 mm, optionally 20 mm or 30 mm or 35 mm or 65 mm or 75 mm, and / or the mattress further comprises a spring portion provided between two layers and, optionally, the spring portion is a pocket spring portion, an enclosure of the pocket springs being formed of agglomerated foam.

10. A mattress according to any of the claims 7-9 wherein it comprises more than one inner layer, each inner layer being provided between two enveloping layers, optionally a same enveloping layer being a bottom layer for a top inner layer and a top layer for a bottom inner layer, the top inner layer being arranged above the bottom inner layer in the set of layers of the mattress and / or an inner layer is a mixed inner layer, comprising one or more agglomerated foam portions and one or more standard foam portions.

11. A mattress according to any of the claims 7-10, wherein the total thickness of the mattress is of 15-35 cm and / or the total length of the mattress is of 90-250 cm, optionally 180-210 cm, optionally 190 or 200 cm and / or the total width of the mattress is of 50-240 cm, optionally 60-210 cm, optionally 70-200 cm, optionally 70, 80, 90, 100, 110, 120, 135, 140, 150, 160, 170, 190, 200 cm.

12. Use of the agglomerated foam layer of any of the claims 1-6 as a layer in a mattress, the mattress being rolled, folded or folded and rolled and packaged in vacuum within a plastic cover.

13. A method of producing an agglomerated foam layer for a mattress, the method comprising compressing foam to obtain compressed foam pieces by providing an ensemble of shredded or granulated foam pieces and compressing such ensemble of foam pieces to a volume corresponding to 65 to 95 % of its total volume before compression, or providing a foam portion, compressing such foam portion to a volume corresponding to 65 to 95 % of its total volume before compression and subsequently shredding or granulating the foam portion into foam pieces, agglomerating the foam pieces by means of bonding with a binding agent, and thereby obtaining an agglomerated foam layer or obtaining an agglomerated foam block and cutting such block to obtain a foam layer for a mattress.

14. A method of producing an agglomerated foam layer according to the previous claim wherein the compression is to a volume corresponding 70 to 95 % of the total volume of the foam before compression, optionally 75 to 85 %.

15. A method of producing an agglomerated foam layer according to any of the claims 25-26 wherein the compression is performed during 300 to 2,200 hours, optionally 720 to 1,440 hours.

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