A memory foam block

Abstract

The present invention provides a memory foam block (1) suitable for use as a mattress, pillow, or cushion. The memory foam block (1) comprises a lower layer (2) of memory foam having an upper side and a lower side; an upper layer (3) of memory foam having an upper side and a lower side; a plurality of crystals (4) having a size of between 5mm and 35mm positioned on the upper side of the lower layer; wherein: the upper side of the lower layer (2) and the lower side of the upper layer (3) are adhered to one another around a periphery to form a single contiguous block (1). The present invention also provides a method of manufacturing a memory foam block (1) according to the present invention.

Description

A Memory Foam Block

[0001] The present invention relates to memory foam blocks suitable for use as mattresses, pillows, and cushions.

[0002] Memory foam, also known as viscoelastic foam, is a well-known material that is commonly used to form mattresses, pillows, and cushions as well as other uses. Examples of other uses include insoles for shoes and padding for posture problems. The manufacturing of memory foam for any application involves the initial manufacture of a memory foam block.

[0003] Memory foam is manufactured from a number of components:

[0004] Polyols: These are the primary component of memory foam and are typically made from polyether or polyester. Polyols provide the softness and flexibility of the foam.

[0005] Diisocyanates: Diisocyanates react with polyols to form the polyurethane polymer that gives memory foam its structure and resilience. Common diisocyanates used include toluene diisocyanate (TDI) and diphenylmethane diisocyanate (MDI).

[0006] Catalysts: Catalysts are used to speed up the reaction between polyols and diisocyanates, allowing the foam to cure more quickly. Common catalysts include tertiary amines and organometallic compounds.

[0007] Blowing Agents: Blowing agents are added to generate carbon dioxide gas, which creates the foam's cellular structure and contributes to its lightweight and porous properties. Common blowing agents include water and fluorocarbons.

[0008] Additives: Additives are incorporated into the foam formulation to enhance specific properties such as flame retardancy, antimicrobial properties, or breathability. Examples of additives include flame retardants, antimicrobial agents, antioxidants, and surfactants.

[0009] In addition, the properties of the memory foam can be controlled by varying the processing conditions such as temperature, pressure, and mixing time during the manufacturing process to ensure proper foaming and curing of the foam. The manufacturing process may involve additional steps such as moulding, cutting, and finishing to produce the final memory foam.

[0010] An example of a typical formulation for memory foam may involve the following proportions:- Polyols: 30% to 40% by weight- Diisocyanates: 60% to 70% by weight- Catalysts: 0.1% to 1% by weight- Blowing Agents: 1% to 10% by weight- Additives: less than 5% by weight

[0011] The manufacture of memory foams can be carried out as follows

[0012] Step 1: Mixing the Ingredients:- Polyols, diisocyanates, catalysts, blowing agents, and additives are precisely measured and mixed together in a reactor vessel. The mixture may also undergo degassing to remove any air bubbles.

[0013] Step 2: Reacting and Foaming:- The mixed ingredients undergo a chemical reaction known as polymerisation, where polyols react with diisocyanates to form polyurethane. This reaction generates heat and produces carbon dioxide gas from the blowing agents, causing the mixture to foam and expand.

[0014] Step 3: Pouring and Shaping:- The foamed mixture is poured into moulds or onto conveyor belts in a controlled environment to prevent contamination and ensure consistent quality. The foam may be shaped into various forms such as sheets, blocks, or contours for mattresses, mattresses toppers, pillows, or cushions.

[0015] Step 4: Curing and Cooling:- The poured foam undergoes a curing process where it solidifies into its final form. The curing time can vary depending on factors such as foam density, thickness, and environmental conditions. Typically, it takes several minutes to several hours for the foam to fully cure.

[0016] - Once cured, the foam is cooled to room temperature to stabilize its properties and make it safe to handle.

[0017] It is to be understood that the above is merely an example of the manufacture of memory foam. The manufacture and optimization of memory foam will be well-known to the person skilled in the art. Any such memory foam block is suitable for use in the present invention.

[0018] Many crystals are believed to have healing properties. Many semi-precious gems and crystals such as quartz, agate, amethyst or opal are believed to have these properties. These gems and crystals are believed to be able to boost low energy, prevent bad energy, release blocked energy, and change or transform aura. For the purpose of this application we refer to all such gems and crystals as “crystals”. Any reference to “crystals” is to be understood to relate to any gem or crystal commonly believed to have healing properties when utilized in crystal healing practices.

[0019] Crystal healing can involve positioning crystals on or around a person’s body to provide a healing energy grid around a body. The selection and positioning of the crystals is decided by a practitioner on the basis of well-known teaching.

[0020] The present invention provides a memory foam block comprising: a lower layer of memory foam having an upper side and a lower side; an upper layer of memory foam having an upper side and a lower side;a plurality of crystals having a size of between 5mm and 35mm positioned on the upper side of the lower layer; wherein:the upper side of the lower layer and the lower side of the upper layer are adhered to one another around a periphery to form a single contiguous block.

[0021] The memory foam of the present invention can be any memory foam known to the person skilled in the art, for example as discussed in the background section of this specification.

[0022] The crystals of the present invention may comprise any crystal or gem used in crystal therapy. This includes but is not limited to amethyst, jade, rose quartz, plane quartz, and citrine. The crystals may all be of a single type or may be a mix of one or more types of crystal.

[0023] The crystals can be distributed within the memory foam according to a defined gem map or predetermined layout in accordance with best practices. This can ensure consistency in the placement of the crystals thereby maximizing their natural properties, the support provided by the memory foam block, and the comfort of the user.

[0024] The lower layer of the memory foam block is preferably adhered to the upper layer using a non-toxic water-based adhesive. As will be readily appreciated the adhesive should be suitable for use with memory foams. Many such adhesives will be apparent to the person skilled in the art.

[0025] The present invention also provides a method of manufacturing a memory foam block according to the present invention, comprising the steps of:providing a memory foam block;cutting the memory foam block into a lower layer and an upper layer; distributing the crystals over the upper side of the lower layer;providing an adhesive around a periphery of the upper side of the lower layer; and adhering the lower side of the upper layer to the upper side of the lower layer around a periphery.

[0026] As an alternative to cutting a single block into a lower layer and an upper layer two conforming layers of memory foam may be provided.

[0027] In order to ensure that the crystals are securely embedded in the memory foam the method of the present invention may further comprise a step wherein the crystals are gently pressed into the upper side of the lower layer after being distributed on the upper side of the lower layer. This can be done manually or with the use of a machine.

[0028] Before being embedded in the memory foam the crystals may undergo suitable pretreatment. This pretreatment may include cleaning in distilled water, milling, grading, or any other suitable pretreatment. In some embodiments, for example for amethyst crystals it may be advantageous that the crystals are charged in moonlight for no less than 2, 4, 6, 8, 10, or 12 hours before being distributed on the upper side of the lower layer of memory foam.

[0029] In some embodiments of method of the invention the crystals and the memory foam may be thermally annealed after step (v). This can involve heating the memory foam block to a temperature suitable for annealing memory foam and holding the memory foam block at that temperature for a period of time, for example 10, 20, 30, 45, or 60 minutes. Pressure may also be applied during any annealing process.

[0030] Conventionally crystal healing requires the appropriate disposition of crystals relative to the subject on each use. Solution to Problem

[0031] The present invention is advantageous in that it provides a memory foam block, suitable for use as a mattress, a pillow, a cushion or any other similar use, wherein the memory foam block has crystals embedded therein suitable for use in crystal therapy. This can provide a therapeutic item for use in crystal healing. The crystals are embedded within the memory foam block so are fixed in position and do not need to be moved and located for each use.

[0032] Features and advantages of the present invention will be apparent from the embodiment shown in the Figures and described below.

[0033] Embodiments of a memory foam block and method according to the present invention will now be described by way of example only, with reference to the accompanying figures, in which.

[0034] is a schematic of an exploded memory foam block according to the present invention;

[0035] is a gem map for distributing crystals in a memory foam block according to the present invention

[0036] A memory foam block 1 according to the present invention is shown in. The memory foam block 1 comprises a lower memory foam layer 2, an upper memory foam layer 3, and a plurality of amethyst crystals 4. The lower layer 2 and the upper layer 3 conform to one another and are formed by cutting a single block of memory foam into two layers. The amethyst crystals 4 are of a substantially uniform size of between 5mm and 35mm and are distributed over the upper side of the lower layer 1 according to a gem map 10. The memory foam block 1 may be used as a pillow.

[0037] In use, the lower layer 2 is adhered to the upper layer 3 by means of a memory foam adhesive 5 provided around a periphery of the upper side of the lower layer and around a periphery of the lower side of the upper layer to form a single unitary block of memory foam. The adhesive 5 is a non-toxic, water-based adhesive.

[0038] The gem map 10 is shown in. The dark lines of the gem map 10 indicate where the crystals 4 are located on the upper side of the lower layer 2. The gem map 10 is provided to locate the crystals in accordance with best practice in crystal therapy to provide the maximum effect when the memory foam block 1 is in use.

[0039] The memory foam block 1 is formed in the current manner. A single memory foam block 1 is provided as a unitary block. This foam block is then cut into two layers of equal thickness; a lower layer 2, and a upper layer 3 and the two layers are separated.

[0040] A plurality of amethyst crystals 4 are provided. The amethyst crystals 4 have been cleaned in distilled water and charged in moonlight for at least 12 hours. The amethyst crystals 4 are then evenly distributed over the upper side of the lower layer 2 in accordance with the gem map. The amethyst crystals 4 are then gently pressed into the upper side of the lower layer 2. The memory foam adhesive 5 is then provided around the periphery of the upper side of the lower layer 2 and the periphery of the lower side of the upper layer 3 as a thin even layer. The upper layer 3 is then aligned with the lower layer 2 and the two layers are pressed together firmly and held in position for at least 5 minutes. The memory foam block 1 is then left for the period of time specified by the adhesive manufacture to allow the glue to cure and to provide a strong and durable bond. Finally, if required, the memory foam block 1 may be cut or shaped into a suitable form.

[0041] Unless otherwise indicated in the claims or by context any feature of the embodiment shown in the drawings may be included in any embodiment of the invention independent from any other feature.

[0042] foam block 1lower memory foam layer 2upper memory foam layer 3a plurality of amethyst crystals 4memory foam adhesive 5gem map 10

Claims

A memory foam block comprising:a lower layer of memory foam having an upper side and a lower side; an upper layer of memory foam having an upper side and a lower side;a plurality of crystals having a size of between 5mm and 35mm positioned on the upper side of the lower layer; wherein:the upper side of the lower layer and the lower side of the upper layer are adhered to one another around a periphery to form a single contiguous block.A memory foam block according to claim 1, wherein the crystals are distributed on the upper side of the lower layer according to a defined gem map.A memory foam block according to claim 1 or claim 2, wherein a water-based adhesive is used to adhere the lower layer to the upper layer.A memory foam block according to any preceding claim, wherein the crystals comprise one or more of amethyst, quartz, and jade.A method of manufacturing a memory foam block according to any preceding claim, comprising the steps of:providing a memory foam block;cutting the memory foam block into a lower layer and an upper layer; distributing the crystals over the upper side of the lower layer;providing an adhesive around a periphery of the upper side of the lower layer; and adhering the lower side of the upper layer to the upper side of the lower layer around a periphery.A method according to claim 5, wherein the crystals are gently pressed into the upper side of the lower layer after being distributed on the upper side of the lower layerA method according to claim 5 or claim 6, wherein the crystals are cleaned in distilled water prior to distribution on the upper side of the lower layer.A method according to any of claims 5 to 7, wherein the crystals are charged in moonlight for no less than 12 hours before being distributed on the upper side of the lower layer.A method according to any of claims 5 to 8, wherein the crystals and memory foam are thermally annealed after step (v).

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