Pre-conditioned foam pad

Abstract

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

Description

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

AI Technical Summary

Benefits of technology

The patent text describes a method for improving the consistency and firmness of mattresses and cushioning foam pads over time and multiple uses. The method involves pre-conditioning or pre-stressing the foam pad or mattress by applying a force across a major surface of the mattress to temporarily compress the height of the foam and break or open closed cells. This pre-conditioning can be done by repeatedly pressing a platen against the mattress or foam pad or passing it under rollers or through complementary pairs of rollers. The method helps to overcome limitations of current methods and ensures a consistent and comfortable mattress for users.

Problems solved by technology

These closed cell windows can be broken or ruptured by repeatedly stressing the material through compression and / or stretching such as those during the regular daily use of a mattress.

However, air may be trapped within the closed cells, and air flow through the foam may be limited if there is a large number of closed or only partially open cells.

If the same foam is then tested again, and again, the hardness is likely to go down a little bit on each successive test cycle because the cell windows in the foam are getting blown open or ruptured allowing air to pass through the foam more freely.

If these cell windows are not crushed open immediately, the foam pad is likely to lose dimensions and shrink.

However, foams used in mattresses or cushions are not generally not made by such a molding process and consequently are not commonly thought to have carbon dioxide trapped in closed cells.

Therefore, foam and mattress manufacturers have not thought to pass foam mattresses or cushioning foam pads through rollers for pre-conditioning and stabilizing firmness.

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