Food-grade polyethylene mattress

Abstract

A non-toxic mattress and method of constructing the mattress having a reduced toxicity has an outer layer of a material selected from the group comprising polyethylene and polylactic acid film. Also, a mattress cover for covering the outer layer of the mattress can also be constructed from a material selected from the same group of materials. The polyethylene and polylactic acid films are non-toxic materials which reduce adverse human allergenic reactions or exposure to potentially harmful chemicals used in the mattress construction.

What is claimed is: 
     
         1 . A mattress comprising:
 a Food Grade Low Density Polyethylene cover;   an outer material in contact with the Food Grade Low Density Polyethylene cover; and   an inner material in contact with the outer material.   
     
     
         2 . The mattress of  claim 1 , wherein the Food Grade Low Density Polyethylene has a density of 0.85 to 1.00 grams per cubic centimeter; a maximum extractable fraction (expressed as percent by weight of the polymer) in N-Hexane at specified temperatures is 5.5% at 50 Degrees Centigrade (Deg C); and a maximum extractable fraction (expressed as percent by weight of the polymer) in Xylene at specified temperatures is 11.3% at 25 Deg C. 
     
     
         3 . The mattress of  claim 1 , wherein the Food Grade Low Density Polyethylene cover is heat fused to the outer material. 
     
     
         4 . The mattress of  claim 3 , wherein the outer material is constructed of cotton, polyester, polypropylene, polylactic acid, wool, polyurethane, and combinations thereof. 
     
     
         5 . The mattress of  claim 1 , wherein the mattress comprises an additional layer composed of a fabric flame barrier and flame retardant. 
     
     
         6 . The mattress of  claim 1 , wherein the inner material is constructed of a material selected from the group consisting of cotton batting, Food Grade Low Density Polyethylene, polyethylene, metal, polyester, polyurethane, and polylactic acid to providing vibration dampening, insulation, and cushioning. 
     
     
         7 . The mattress of  claim 1 , wherein the inner material is constructed of a support material that maintains a shape of the mattress. 
     
     
         8 . A method to prepare a mattress, comprising the steps of:
 forming a Food Grade Low Density Polyethylene cover;   forming an outer layer contacting the Food Grade Low Density Polyethylene cover; and   forming an inner material contacting the outer material.   
     
     
         9 . The method of  claim 8 , wherein the Food Grade Low Density Polyethylene has a density of 0.85 to 1.00 grams per cubic centimeter; a maximum extractable fraction (expressed as percent by weight of the polymer) in N-Hexane at specified temperatures is 5.5% at 50 Degrees Centigrade (Deg C); and a maximum extractable fraction (expressed as percent by weight of the polymer) in Xylene at specified temperatures is 11.3% at 25 Deg C. 
     
     
         10 . The method of  claim 8 , wherein the Food Grade Low Density Polyethylene cover is heat fused to the outer material. 
     
     
         11 . The method of  claim 10 , wherein the outer material is constructed of cotton, polyester, polypropylene, polylactic acid, wool, polyurethane, and combinations thereof. 
     
     
         12 . The method of  claim 8 , wherein the mattress comprises an additional layer composed of a fabric flame barrier and flame retardant. 
     
     
         13 . The method of  claim 8 , wherein the inner material is constructed of a material selected from the group consisting of cotton batting, Food Grade Low Density Polyethylene, polyethylene, metal, polyester, polyurethane, and polylactic acid to providing vibration dampening, insulation, and cushioning. 
     
     
         14 . The method of  claim 8 , wherein the inner material is constructed of a support material that maintains a shape of the mattress. 
     
     
         15 . The mattress of  claim 1 , wherein the Food Grade Low Density Polyethylene cover can be in close proximity to or in contact with a user's skin. 
     
     
         16 . The method of  claim 8 , wherein the Food Grade Low Density Polyethylene cover can be in close proximity to or in contact with a user's skin. 
     
     
         17 . The mattress of  claim 1 , wherein the mattress is sized to fit a basinet, crib, cradle, or bed. 
     
     
         18 . The method of  claim 8 , wherein the mattress is sized to fit a basinet, crib, cradle, or bed.