Rebond polyurethane foam in mattress construction

Abstract

The foam assemblies for use in a mattress are made from rebond foam blocks that have been shaped, such as by relief-cutting, to achieve desired firmness characteristics for a mattress support layer. The rebond foam blocks may have surface relief cuts or channels formed on interior surfaces of an assembly of foam components. Shapes may include ridges, features, or other shapes formed from or relief-cut into rebond foam blocks. The desired geometric features may be cut into sheets of rebond foam or formed by rebond foam components sandwiched between or attached to one or more foam layers. The features may create channels through the interior of the foam assembly. The rebond foam assemblies may be combined with other foam or non-foam components to form a mattress.

Description

REBOND POLYURETHANE FOAM IN MATTRESS CONSTRUCTIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 655,977 filed on June 4, 2024, the disclosure of which is incorporated herein by reference.BACKGROUNDField of the Invention

[0002] This disclosure is in the field of mattress construction. More specifically, this disclosure is in the field of constructing mattresses using bonded polyurethane foam. More specifically, this disclosure is in the field of utilizing shaped, such as relief-cut, bonded polyurethane foam components instead of conventional foam, innersprings, or other materials used in conventional mattress construction.Description of the Related Art

[0003] Typical mattress construction comprises a support layer sandwiched between a base layer and a comfort layer. The support layer is often made from virgin foam or springs. Bonded polyurethane foam is suitable for use as a support layer in a mattress. Improved designs can be achieved by relief cutting the bonded material to attain the desired IFD, support factor, and weight.SUMMARY OF THE INVENTION

[0004] In various embodiments, the invention comprises a foam component for use in a mattress, the foam component comprising a foam block made of rebond foam wherein at least one surface of the foam block incorporates a plurality of relief cuts. In some embodiments of the inventive foam component the plurality of relief cuts reduce the weight of the foam block. In some embodiments of the inventive foam component the relief cuts form a plurality of ridges. In some embodiments of the inventive foam component the relief cuts form a plurality of features extending outwardly from the surface of the foam component.

[0005] In some embodiments of the inventive foam component each feature of the plurality of features is a frustum of a pyramid. In other embodiments of the inventive foam component each feature of the plurality of features is a columnar solid.

[0006] In some embodiments of the inventive foam component the rebond foam has a grind size of greater than 1 inch. In some embodiments of the inventive foam component the foam block has a density of less than 3 pounds per cubic foot.

[0007] In some embodiments the invention comprises a foam assembly for use in a mattress, the foam assembly comprising a foam layer, a plurality of foam features attached to the foam layer, wherein each of the plurality of foam features are formed from rebond foam material. In some embodiments of the inventive foam assembly the SF of the foam assembly is in the range of 2.5 to 3.5.

[0008] In some embodiments of the inventive foam assembly each of the plurality of foam features comprises a frustum of a pyramid. In other embodiments of the inventive foam assembly each of the foam features is a columnar solid. In other embodiments of the inventive foam assembly each of the foam features is a ridge. In some embodiments of the inventive foam assembly the rebond foam material has a grind size of greater than 1 inch. In some embodiments of the inventive foam assembly, the rebond foam material has a density of less than 3 pounds per cubic foot.

[0009] In other embodiments the invention comprises a foam assembly for use in a mattress, the foam assembly comprising a lower foam component having a plurality of features extending upwardly from its top surface; an upper foam component having a plurality of features extending downwardly from its lower surface; wherein the lower foam component and the upper foam component are made from a rebond foam material; and the features on the lower component contact the features on the upper foam component. In some of these embodiments the plurality of features comprise ridges. In some of these embodiments with ridges, the ridges on the upper foam component are perpendicular to the ridges onthe lower foam component. In other embodiments, the features are frustum of a pyramid. In some embodiments, the features are columnar solids.

[0010] The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A preferred embodiment of the invention, illustrative of the best mode in which the applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

[0012] Figure 1 is a cross-sectional view of a conventional mattress.

[0013] Figure 2A is a perspective view of a surface of an embodiment of an inventive rebond foam support layer with relief cuts for a mattress.

[0014] Figure 2B is a perspective view of a mattress constructed with an inventive rebond foam support layer.

[0015] Figure 3A is an upper perspective view of a second embodiment of an inventive rebond foam support layer for a mattress.

[0016] Figure 3B is a lower perspective view of the second embodiment of an inventive rebond foam support layer for a mattress.

[0017] Figure 3C is a perspective view of a portion of the second embodiment of an inventive rebond foam support layer for a mattress.

[0018] Figure 3D is a perspective cut-away view of the second embodiment of an inventive rebond foam support layer for a mattress.

[0019] Figure 3E is a side plan view of the second embodiment of an inventive rebond foam support layer for a mattress.

[0020] Figure 3F is a top plan view of the second embodiment of an inventive rebond foam support layer for a mattress.

[0021] Figure 3G is an end plan view of the second embodiment of an inventive rebond foam support layer for a mattress.

[0022] Figure 4A is an upper perspective view of a third embodiment of an inventive rebond foam support layer for a mattress.

[0023] Figure 4B is a lower perspective view of the third embodiment of an inventive rebond foam support layer for a mattress.

[0024] Figure 4C is a perspective view of a portion of the third embodiment of an inventive rebond foam support layer for a mattress.

[0025] Figure 4D is a perspective cut-away view of the third embodiment of an inventive rebond foam support layer for a mattress.

[0026] Figure 4E is a side plan view of the third embodiment of an inventive rebond foam support layer for a mattress.

[0027] Figure 4F is a top plan view of the third embodiment of an inventive rebond foam support layer for a mattress.

[0028] Figure 4G is an end plan view of the third embodiment of an inventive rebond foam support layer for a mattress.

[0029] Figure 5A is an upper perspective view of a fourth embodiment of an inventive rebond foam support layer for a mattress.

[0030] Figure 5B is a lower perspective view of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0031] Figure 5C is a perspective view of a portion of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0032] Figure 5D is a perspective cut-away view of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0033] Figure 5E is a side plan view of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0034] Figure 5F is a top plan view of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0035] Figure 5G is an end plan view of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0036] Figure 6 is a perspective view of the fourth embodiment of an inventive rebond foam support layer for a mattress.

[0037] Figure 7 is a side view of a lower portion of the third or fourth embodiment of an inventive rebond foam support layer for a mattress.

[0038] Figure 8A is a perspective view of a portion of a fifth embodiment of an inventive rebond foam support layer for a mattress.

[0039] Figure 8B is a perspective view of a portion of the fifth embodiment of an inventive rebond foam support layer for a mattress.

[0040] Figure 8C is a side view of a portion of the fifth embodiment of an inventive rebond foam support layer for a mattress.

[0041] Figure 9A is a perspective view of a portion of a sixth embodiment of an inventive rebond foam support layer for a mattress.

[0042] Figure 9B is a perspective view of a portion of the sixth embodiment of an inventive rebond foam support layer for a mattress.

[0043] Figure 9C is a side view of a portion of the sixth embodiment of an inventive rebond foam support layer for a mattress.

[0044] Figure 10A is a perspective view of a portion of a seventh embodiment of an inventive rebond foam support layer for a mattress.

[0045] Figure 10B is a perspective view of a portion of the seventh embodiment of an inventive rebond foam support layer for a mattress.

[0046] Figure 10C is a side view of a portion of the seventh embodiment of an inventive rebond foam support layer for a mattress.

[0047] Figure 11 is a perspective view of an eighth embodiment of an inventive rebond support layer for a mattress.DETAILED DESCRIPTION

[0048] As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

[0049] In varying embodiments, the invention is directed toward building mattresses that utilize reliefcut bonded polyurethane foam (rebond) to replace conventional foam, innersprings, or other materials used to provide a support layer for a mattress. In embodiments of the invention described and claimedherein, relief-cut rebond is an engineered composite material primarily made of shredded polyurethane foam pieces, fibrous or cellular bits, along with other materials that are molded and glued together, then cut to strategically remove sections of the composite foam to adjust the final properties of the piece of material. Alternately, relief-cut rebond in some embodiments will incorporate fall off from a branded process or products that are shredded, blended with other materials, then molded into a branded final product.

[0050] Conventional mattress construction, such as that shown in Figure 1, typically consists of several layers of conventional, HR, gel, viscoelastic polyurethane foam, latex foams, or innersprings to achieve various attributes of firmness, support factor, cooling, etc. Although there are infinite combinations of embodiments of the invention, the general mattress construction utilizes three general sections made up of one or more components: base layer 100, support layer 102 (with or without rails 104), and comfort layer 106. While each layer has a specific function, they all work in tandem to give a mattress its overall feel. The support layer 102 is the main section providing support and typically utilizes either springs or virgin foam. Perimeter rails 104 around the support layer 102 are used in some constructions to provide extra support when sitting on the edge of the mattress. The support layer 102 is typically made from virgin foam or springs, which can be expensive.

[0051] Bonded polyurethane foam (rebond foam) is made from bonding small pieces of foam to create a large foam sheet. The small pieces of foam in some embodiments are larger foam pieces that are ground to a desired size, such as the off cuts from a manufacturing process for foam or scrap / off cuts from a manufacturing process for products that incorporate foam components, such as athletic shoes, furniture, and other products. The properties of the rebond foam in various embodiments are adjusted by varying parameters including the grain / grind size of the foam pieces used to form the rebond foam, among other parameters. In some embodiments of the inventive foam components, the grain size may be greater than1 inch. In other embodiments of the inventive foam components, the grain size may be less than 1 inch.

[0052] There are challenges to using standard rebond foam as the support layer 102 in mattresses. First, rebond foam is heavier than virgin polyurethane foam. Rebond foam densities for mattress use typically range from 3.0 to 5.0 lbs. per cubic foot (though other density rebond foam may be used), whereas virgin polyurethane foam density is typically in the 1.2-2.0 lbs. per cubic foot range. As a result, using standard rebond foam in a mattress causes an overall increase in weight of the finished mattress, making it more difficult to handle and increasing the load on the bedframe.

[0053] Second, standard rebond foam has a much higher Indention Force Deflection (IFD) and Support Factor (SF). IFD is a measure of load bearing or firmness at a given deflection of the foam. For example, 25% IFD means the force or firmness of a material measured at 25% compression. SF is the ratio of the 65% IFD divided by the 25% IFD and gives an indication of cushioning quality. The higher the SF, the firmer the material gets as one sinks into it. Conversely, the lower the SF is, the more prone one is to bottom out when a weight such as a person's body is placed on the mattress resulting in inferior performance. There is a range of SF values that are preferable for mattresses comfort. The use of unaltered bonded foam slabs in the support layer often results in a very firm mattress that is not within the desired or optimal ranges for SF.

[0054] The range of IFD for solid rebond foam blocks, not yet processed by relief cutting or other versions of the inventive process, may vary widely, and for some rebond foam materials it may be in the range of 20 to 150 with an SF from 3.0 to 5.0. Many solid rebond foam materials have an IFD from 25 to 50 prior to relief cutting. In some embodiments of the inventive foam support layer, after relief cutting, assembly of foam components, or other shaping, the foam assembly may have a SF of 2.5 to 3.5. In other embodiments the SF of the inventive support layer may be higher or lower than that range.

[0055] Some embodiments of the inventive rebond foam material and components are improved for use in mattresses by relief cutting the rebond foam prior to incorporating it into the mattress. In varyingembodiments of the inventive rebond foam components, convolution or relief-cutting of the rebond foam material comprises forming or cutting the rebond foam into components with undulating surfaces, channels, "zig-zags", circles, pillars, cross-hatches, ridges, grooves or other patterns in one or more surface of the foam components. An unlimited variety of relief cut components are created in various embodiments of the inventive concept using the foregoing operations and other similar operations, and varying the pattern, height, depth, and thicknesses used to make the relief cuts and form the components of the assembly. In some embodiments one or more rebond foam components are formed into a rebond foam assembly with a geometry that creates relief features in the foam assembly.

[0056] In some embodiments the inventive rebond foam component of the mattress is formed with internal cavities or channels in the foam component used to form the support layer. In some embodiments these cavities or channels are formed by cutting rebond foam into ridged, grooved, or pillar shapes and assembling the components into a rebond foam assembly. In some embodiments the ridges, grooves, or pillars align to create cavities or channels in the interior of the rebond foam assembly. In some embodiments all or part of the foam components are formed by molding a foam blank to the desired shape instead of, or in addition to, cutting the foam blank.

[0057] In some embodiments the rails described above are formed by relief cuts in the perimeter of a rebond foam component and a pattern of relief cuts is formed in another section of the rebond foam component to form the support layer. By varying the relief cuts in different parts of embodiments of the rebond foam component, the properties of the single rebond foam component are capable of being tailored to replace three or more pieces of foam that would be glued together in a conventional mattress.

[0058] Rebond foam components or assemblies that have been shaped in the inventive manner described herein are capable of being used in mattresses to replace conventional inner springs, virgin foam, or both, for the support layer or other components of the mattress. Building a mattress with theinventive relief-cut foam assemblies to replace innersprings, which are typically made of metal, improves the recyclability of the mattress. End of life deconstruction of the mattress is eliminated or significantly reduced, and metal contamination is no longer of concern. This creates an easier recycling process with higher quality output scrap to be used as an input into another upcycled product.

[0059] One embodiment of the inventive shaped rebond foam is depicted in Figure 2A. In this embodiment, one or both of the upper and lower surfaces of the rebond foam component have been shaped into an undulating topology. This topology reduces the overall weight of the foam component and results in a foam component with improved IFD and SF characteristics. A mattress constructed with a support layer 102 formed partially from the inventive foam component is depicted in Figure 2B. In the depicted mattress, layers A, C, and D are formed of virgin foam of varying characteristics, though in other embodiments some or all of these layers may be formed from rebond foam as well. Layer B is a layer of the inventive rebond foam with a single upper convoluted or relief-cut surface. In other embodiments the topology is varied in the width and amplitude of the surface fluctuations, and in the shapes of the protruding or inset areas. For example, in some embodiments the protrusions or the inset areas are more pyramidal in shape than the ovoid topology depicted in the figures. In other embodiments other surface topologies are used in place of the specific depicted topology with similar results.

[0060] An additional embodiment of the inventive foam support layer 102 is depicted in Figures 3A through 3G. In these embodiments the inventive rebond foam support layer 102 is formed as an assembly 300 of two convoluted foam components 302 and 304. In the depicted embodiment the upper foam component 302 is provided with ridges 306 on its lower surface, and lower foam component 304 is provided with ridges 308 on its upper surface. In the depicted embodiment the components 302 and 304 are 3 inches thick at their thickest point at the ridges and 1 inch thick in the thinnest areas at the bottom of the channels between the ridges 306 and 308. The depicted embodiment is 60 inches by 80 inches in width and length, respectively. Other dimensions are used in other embodiments as necessary to fit aparticular bed size. In the depicted embodiment the ridges are 2 inches tall, 3 inches wide at their outer surface and widen at their base, so that the depicted ridges are 4 inches wide at their base where they attach to or are formed as part of the component 302 or 304. In the depicted embodiment, the channels are 3 inches wide at the bottom of each channel. These dimensions are depicted on Figure 7. In other embodiments the features may have different dimensions from the depicted embodiments.

[0061] In the depicted embodiment, ridges 306 extend parallel to the longitudinal axis of the upper component 302, and ridges 308 extend parallel to the transverse axis of the lower component 304. In some embodiments, the upper component 302 and lower component 304 are attached to each other via welding, adhesive, or other method known in the art of attaching foam pieces with the ridges contacting each other intermittently to form interconnected channels that extend longitudinally, transversely, and in an undulating grid. In some embodiments the channels and ridges of each component are cut from a single foam block. In other embodiments the ridges 308 are separately cut from a foam block and then adhered or joined to a sheet. In some embodiments the foam assembly 300 is used as a support layer in a mattress.

[0062] In the embodiment depicted in Figures 3A through 3G, the ridges 306 extend perpendicularly to the ridges 308. In some of these embodiments, the ridges 306 extend from a left side to a right side of the support layer 300 while the ridges 308 extend from a head end to a foot end of the support layer 300. In other embodiments the orientation of the ridges is rotated by 90 degrees from the depicted embodiment so that ridges 308 run from side to side and ridges 306 run from head to foot of the support layer. In some embodiments the ridges are rotated 45 degrees or some other amount from the depicted embodiment. In some embodiments the ridges 306 and 308 extend perpendicularly to each other. In some embodiments the ridges 306 and 308 extend in a non-perpendicular and non-parallel direction with respect to each other.

[0063] An additional embodiment of the inventive foam support layer 102 is depicted in Figures 4A through 4G. In this embodiment and related embodiments, the support layer 102 comprises an assembly 400 of an upper foam component 402 and a lower foam component 404. In this embodiment, each component 402 and 404 comprises a sheet of rebond foam with support features 406 and 408 extending respectively from the lower and upper surfaces of the sheet of foam. In the depicted embodiment the features comprise frusto-pyramidal solids, though in other embodiments the features comprise frusto- conical solids, rectangular solids, cylindrical solids, inverted frusto-pyramidal solids, inverted frusto- conical solids, frustum of other solids, polyhedrons, or other solid shapes.

[0064] In the embodiment depicted in Figures 4A through 4G the lower surfaces of features 406 mate with or contact the upper surfaces of features 408 when the two components are assembled to form the support layer 400. In some embodiments these upper and lower surfaces are adhered, joined, bonded, or otherwise attached to each other.

[0065] An additional embodiment of the inventive foam support layer 102 is depicted in Figures 5A through 5G. In this embodiment and related embodiments, the support layer 102 comprises an assembly 500 of an upper foam component 502 and a lower foam component 504. In this depicted embodiment the upper foam component 502 is provided with ridges 506 on its lower surface, and lower foam component 504 is provided with ridges 508 on its upper surface. The ridges 506 and 508 in this embodiment are of similar size and shape as those described in relation to Figures 3A through 3G above, however other sizes and configurations are used in other embodiments. In some of these embodiments, the ridges 506 extend in a direction that is parallel to the ridges 508. In some of these embodiments, the ridges 506 and 508 extend from side to side, transversely, of the support layer 500. In some of these embodiments, the ridges 506 and 508 extend from end to end, head to foot, longitudinally, across the support layer 500.

[0066] In the embodiment depicted in Figures 5A through 5G the lower surfaces of features 506 mate with or contact the upper surfaces of features 508 when the two components are assembled to form the support layer 500. In some embodiments these upper and lower surfaces are adhered, joined, bonded, or otherwise attached to each other. Figure 6 depicts an embodiment of an assembled support layer 500 with transversely running ridges on each upper and lower component with the ridges mated to each other to create transverse channels through the support layer 500.

[0067] In some embodiments of the support layer 102, features with more complex geometric shapes are utilized to create desired physical properties in the support layer 102. For example, in the embodiment depicted in Figures 8A through 8C, an embodiment of a support layer 800 is depicted with multiple features 804 contained between a lower foam layer 802 and an upper foam layer 806. In Figures 8A and 8C the embodiment is depicted with the top foam layer 806 removed for visibility. In various embodiments of the depicted embodiment, the features 804 comprise a dodecahedron, octahedron, or other similar shapes with more or fewer faces, or with semi-conical components. As described above in varying embodiments each feature 804 is capable of being assembled from multiple parts or cut from a single block of rebond foam. In some embodiments the features 804 are attached or joined to one or both of the lower foam layer 802 and the upper foam layer 806. In some embodiments of the support layer 800 the features are attached only to one foam layer, either 802 or 806.

[0068] Some embodiments have dimensions in inches as specified in Figure 8C, for example, which discloses an embodiment with features 804 that are 5 inches in height, 4 inches in width at their widest point, and 3 inches across on the upper and lower surfaces, separated approximately 2.5 inches at their top and bottom surfaces and approximately 1 inch apart at their closest proximity. The size and spacing of the features 804 are varied in different embodiments to achieve a desired firmness as measured by theIFD and SF characteristics or the weight of the overall mattress.

[0069] In some embodiments, such as those depicted in Figures 9A through 9C, the support layer 900 comprises a lower foam layer 902, features 904, and a top foam layer 906. In Figures 9A and 9C the embodiment is depicted with the top foam layer 906 removed for visibility. In some of these embodiments the features 904 comprise columnar shapes with a cylindrical or square cross-section having wider sections, or flanges near the top, the bottom, or both. In some of these embodiments, the features 904 have a spool shape, or are formed with one or more cove cuts or channels around their sides. As described above in varying embodiments each feature 904 is capable of being assembled from multiple parts or cut from a single block of rebond foam. In some embodiments the features 904 are attached or joined to one or both of the lower foam layer 902 and the upper foam layer 906. In some embodiments of the support layer 900 the features are attached only to one foam layer, either 902 or 906.

[0070] Some embodiments have dimensions in inches as specified in Figure 9C, for example, which discloses an embodiment with features 904 that are 5 inches in height, 4 inches in width at their widest point near the upper and lower surfaces, and 2.5 inches across at the narrowest point, separated approximately 2.5 inches at their midpoint and approximately 1 inch apart at their closest proximity. The size and spacing of the features 904 is varied in different embodiments to achieve a desired firmness as measured by the IFD and SF characteristics or the weight of the overall mattress.

[0071] In some embodiments, such as those depicted in Figures 10A through 10C, the support layer 1000 comprises a lower foam layer 1002, a plurality of features 1004, and a top foam layer 1006. In Figures IDA and 10C the embodiment is depicted with the top foam layer 1006 removed for visibility. In some of these embodiments, the sides of the features 1004 are arcuate, ovoid, parabolic, spherical, or other curve in aspect. In some embodiments the side surfaces are curved as described above only partially, with planer sections on some sides or on sections of the vertical extent of the feature 1004. As described above in varying embodiments each feature 1004 are capable of being assembled from multiple parts or cut from a single block of rebond foam. In some embodiments the features 1004 are attached or joined to one orboth of the lower foam layer 1002 and the upper foam layer 1006. In some embodiments of the support layer 800 the features are attached only to one foam layer, either 1002 or 1006.

[0072] Some embodiments may have dimensions in inches as specified in Figure IOC, for example, which discloses an embodiment with features 1004 that are 5 inches in height, 4 inches in width at their widest point, and 2.5 inches across on the upper and lower surfaces, separated approximately 2.5 inches at their top and bottom surfaces and approximately 1 inch apart at their closest proximity. The size and spacing of the features 1004 are varied in different embodiments to achieve a desired firmness as measured by the IFD and SF characteristics or the weight of the overall mattress.

[0073] An additional embodiment of the inventive support layer 1100 is depicted in Figure 11. In the depicted embodiment the features in the support layer are formed by cutting holes through the rebond foam block 1102. In the depicted embodiment some of the holes 1104 are cylindrical, some holes 1106 have a diamond cross-section, and some holes 1108 have a triangular cross-section. In other embodiments, the holes may have different cross-sectional shapes or be irregular in cross-sectional shape. In some embodiments, the holes may extend through the entire foam block 1102, while in other embodiments they may extend only partially through the foam block 1102 from either or both sides thereof.

[0074] The following item lists A, B, C, etc. are illustrative, but not limiting, of embodiments of the inventive device. Features of the following item lists may constitute features of the other item lists. The reference numbers provided in the item descriptions are for ease of reference to the figures and shall not be construed as limiting their subject matter.

[0075] Al. A foam component for use in a mattress, the foam component comprising a foam block comprising rebond foam wherein at least one surface of the foam block incorporates a plurality of relief cuts.

[0076] A2. The foam component according to Al wherein the plurality of relief cuts form an undulating topology.

[0077] A3. The foam component according to any of the preceding A items, wherein the relief cuts form a plurality of ridges.

[0078] A4. The foam component according to any of the preceding A items, wherein the relief cuts form a plurality of features extending outwardly from the surface.

[0079] A5. The foam component according to any of the preceding A items, wherein each feature of the plurality of features is a frustum of a pyramid.

[0080] A6. The foam component according to any of the preceding A items, wherein each feature of the plurality of features is a columnar solid.

[0081] A7. The foam component according to any of the preceding A items, wherein the rebond foam has a grind size of greater than 1 inch.

[0082] A8. The foam component according to any of the preceding A items, wherein the foam block has a density of less than 3 pounds per cubic foot.

[0083] Bl. A foam assembly for use in a mattress, the foam assembly comprising a lower foam layer and an upper foam layer; a plurality of foam features disposed between the lower foam layer and the upper foam layer; wherein each of the plurality of foam features are formed from rebond foam material.

[0084] B2. The foam assembly according to Bl wherein the SF of the foam assembly is in the range of 2.5 to 3.5.

[0085] B3. The foam assembly according to any of the preceding B items, wherein each of the plurality of foam features comprises a frustum of a pyramid.

[0086] B4. The foam assembly according to any of the preceding B items, wherein each of the foam features is a columnar solid.

[0087] B5. The foam assembly according to any of the preceding B items, wherein each of the foam features is a ridge.

[0088] B6. The foam assembly according to any of the preceding B items, wherein the rebond foam material has a grind size of greater than 1 inch.

[0089] B7. The foam assembly according to any of the preceding B items, wherein the rebond foam material has a density of less than 3 pounds per cubic foot.

[0090] B8. The foam assembly according to any of the preceding B items, further comprising relief cuts in the foam assembly forming side rails for a mattress.

[0091] Cl. A foam assembly for use in a mattress, the foam assembly comprising a lower foam component having a plurality of features extending upwardly from a top surface thereof; an upper foam component having a plurality of features extending downwardly from a lower surface thereof; wherein the lower foam component and the upper foam component are made from a rebond foam material; and wherein of the plurality of features on the lower component contact the plurality of features on the upper foam component.

[0092] C2. The foam assembly according to item Cl, wherein the plurality of features comprise ridges.

[0093] C3. The foam assembly according to any of the preceding C items, wherein the ridges on the upper foam component are perpendicular to the ridges on the lower foam component.

[0094] C4. The foam assembly according to any of the preceding C items, wherein each of the plurality of features are frustum of a pyramid.

[0095] C5. The foam assembly according to any of the preceding C items, wherein each of the plurality of features are columnar solids.

[0096] C6. The foam assembly according to any of the preceding C items, further comprising relief cuts in the foam assembly to form side rails for a mattress.

[0097] C7. The foam assembly according to any of the preceding C items, wherein the features are spring blocks.

[0098] DI. A process for making a foam assembly for use in a mattress, comprising the steps of cutting relief features into one or more rebond foam blocks, and assembling the one or more foam blocks to create a support layer for a mattress.

[0099] D2. The process for making a foam assembly according to item DI, wherein the one or more rebond foam blocks comprise an upper foam block and a lower foam block, and the step of assembling comprises mating the relief features of the upper foam block to the relief features of the lower foam block.

[0100] D3. The process for making a foam assembly according to any of the preceding D items, wherein the one or more foam blocks comprise spring blocks, and the step of assembling comprises disposing the spring blocks between an upper foam sheet and a lower foam sheet.

[0101] "Substantially", "approximately", or "about" means to be more-or-less conforming to the particular dimension, range, shape, concept, or other aspect modified by the term, such that a feature or component need not conform exactly. For example, a "substantially cylindrical" object means that the object resembles a cylinder but may have one or more deviations from a true cylinder. The terms "about" or "substantially" or "approximately" as used herein indicates the value of a given quantity that can vary based on a particular technology. Based on the particular technology, the term "about" or "substantially"or "approximately" can indicate a value of a given quantity that varies within, for example, 1-15% of the value (e.g., ±1%, ±2%, ±5%, +10%, or ±15% of the value).

[0102] "Comprising," "including," and "having" (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional, unrecited elements or method steps.

[0103] Changes may be made in the above methods, devices and structures without departing from the scope hereof. Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative and exemplary of the invention, rather than restrictive or limiting of the scope thereof. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one of skill in the art to employ the present invention in any appropriately detailed structure. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention.

[0104] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.

[0105] Aspects of the present disclosure are described in detail with reference to aspects thereof as illustrated in the accompanying drawings. References to "one aspect," "an aspect," "some aspects," "an embodiment," "varying embodiments," etc., indicate that the aspect(s) described may include a particular feature, structure, or characteristic, but every aspect or embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to thesame aspect. Further, when a particular feature, structure, or characteristic is described in connection with an aspect, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other aspects whether or not explicitly described.

[0106] Spatially relative terms, such as "beneath," "below," "lower," "above," "on," "upper," "opposite" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or in operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

Claims

CLAIMS1. A foam component for use in a mattress, the foam component comprising: a foam block comprising rebond foam wherein at least one surface of the foam block incorporates a plurality of relief cuts.

2. The foam component of claim 1 wherein the plurality of relief cuts reduce the weight of the foam block.

3. The foam component of claim 1 wherein the relief cuts form a plurality of ridges.

4. The foam component of claim 1 wherein the relief cuts form a plurality of features extending outwardly from the surface of the foam block.

5. The foam component of claim 4 wherein each feature of the plurality of features is a frustum of a pyramid.

6. The foam component of claim 4 wherein each feature of the plurality of features is a columnar solid.

7. The foam component of claim 1 wherein the rebond foam has a grind size of greater than 1 inch.

8. The foam component of claim 1 wherein the foam block has a density of less than 3 pounds per cubic foot.

9. A foam assembly for use in a mattress, the foam assembly comprising: a foam layer; a plurality of foam features attached to the foam layer; wherein each of the plurality of foam features are formed from rebond foam material.

10. The foam assembly of claim 9 wherein the SF of the foam assembly is in the range of 2.5 to 3.5.

11. The foam assembly of claim 9 wherein each of the plurality of foam features comprises a frustum of a pyramid.

12. The foam assembly of claim 9 wherein each of the foam features is a columnar solid.

13. The foam assembly of claim 9 wherein each of the foam features is a ridge.

14. The foam assembly of claim 9 wherein the rebond foam material has a grind size of greater than1 inch.

15. The foam assembly of claim 9 wherein the rebond foam material has a density of less than 3 pounds per cubic foot.

16. A foam assembly for use in a mattress, the foam assembly comprising: a lower foam component having a plurality of features extending upwardly from a top surface thereof; an upper foam component having a plurality of features extending downwardly from a lower surface thereof; wherein the lower foam component and the upper foam component are made from a rebond foam material; and wherein of the plurality of features on the lower component contact the plurality of features on the upper foam component.

17. The foam assembly of claim 16 wherein the plurality of features comprise ridges.

18. The foam assembly of claim 17 wherein the ridges on the upper foam component are perpendicular to the ridges on the lower foam component.

19. The foam assembly of claim 16 wherein each of the plurality of features are frustum of a pyramid.

20. The foam assembly of claim 16 wherein each of the plurality of features are columnar solids.

Images