Mattresses Having a Matrix Core of Foam Elements

Abstract

A mattress is constructed of a core comprising a matrix of foam pieces that are bonded together. The core has a thickness in the range from about 1.5 inches to about 10 inches, and more particularly from about 3 inches to about 8 inches, a density of about 4 pounds to 8 pounds per cubic foot, and an IFD of about 28 to 65. The core has a top surface and a bottom surface. A base layer is coupled to the bottom surface of the core, and a cushion layer is coupled to the top surface.

What is claimed is: 
     
         1 . A mattress comprising:
 a core comprising a matrix of foam pieces that are bonded together, wherein the core has a thickness in the range from about 1.5 inches to about 10 inches, a density of about 4 pounds to 8 pounds, and an IFD of about 28 to 65, the core having a top surface and a bottom surface; and   a cushion layer coupled to the top surface.   
     
     
         2 . The mattress of  claim 1 , wherein the core thickness ranges from about 3 inches to about 8 inches'. 
     
     
         3 . The mattress as in  claim 1 , wherein the cushion layer comprises a visco-elastic material. 
     
     
         4 . The mattress as in  claim 1 , further comprising a top layer positioned above the cushion layer. 
     
     
         5 . The mattress as in  claim 1 , further comprising a cover enveloping the core, the base layer and the cushion layer. 
     
     
         6 . The mattress as in  claim 5 , wherein the cover is quilted. 
     
     
         7 . The mattress as in  claim 5 , wherein the cover has flame retardant or flare resistant features. 
     
     
         8 . The mattress as in  claim 1 , wherein the foam pieces comprise polyurethane, urethane, or a combination thereof 
     
     
         9 . The mattress as in  claim 1 , further comprising a base layer coupled to the bottom surface of the core. 
     
     
         10 . The mattress as in  claim 9 , wherein the base layer comprises a support foam layer. 
     
     
         11 . A method for constructing a mattress, comprising:
 forming a loaf by combining a plurality of foam pieces and a bonding material into a generally rectangular mold and applying heat, wherein the resulting loaf has a top, a bottom and four sides;   cutting a rectangular section from the loaf to form a core, wherein the rectangular section has a thickness in the range from about 1.5 inches to about 10 inches;   attaching a base layer to a bottom surface of the core;   attaching a cushion layer to a top surface of the core.   
     
     
         12 . A method as in  claim 11 , further comprising placing a cover about the mattress. 
     
     
         13 . A method as in  claim 11 , wherein the core has a density in the range from about 4 pounds to about 8 pounds and an IFD in the range from about 28 to about 65. 
     
     
         14 . A method as in  claim 11 , wherein the bonding material comprises a polyurethane binder. 
     
     
         15 . A method as in  claim 11 , wherein the plurality of foam pieces comprise repurposed pieces or remnants from other applications or from foam manufacturing runs that are otherwise unusable.