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.

1 - 15 . (canceled) 
     
     
         16 . A mattress comprising:
 a core comprising a matrix of foam pieces that are adhesively bonded together by coating the foam pieces with a binder or resin and compressing the foam pieces to a desired density up to 8 pounds per cubic foot, wherein the core has a thickness in the range from 3 inches to about 10 inches, and an IFD of about 28 to 65, the core having a top surface and a bottom surface;   a cushion layer coupled to the top surface, wherein the cushion layer comprises a polyurethane foam or latex, has a density in the range from about 2 pounds per cubic foot to about 6 pounds per cubic foot, a height in the range from 2 inches to about 6 inches and an IFD of about 6 to about 18; and   a base layer coupled to the bottom surface of the core, the base layer comprising a support foam layer having a thickness in the range from 0.25 inch to 2 inches with a density of about 1 pound per cubic foot to about 2 pounds per cubic foot and an IFD of about 28 to about 70.   
     
     
         17 . The mattress of  claim 16 , wherein the core thickness ranges from 4 inches to about 8 inches. 
     
     
         18 . The mattress as in  claim 16 , wherein the cushion layer comprises a visco-elastic material. 
     
     
         19 . The mattress as in  claim 16 , further comprising a top layer positioned above the cushion layer. 
     
     
         20 . The mattress as in  claim 16 , further comprising a cover enveloping the core, the base layer and the cushion layer. 
     
     
         21 . The mattress as in  claim 20 , wherein the cover is quilted. 
     
     
         22 . The mattress as in  claim 20 , wherein the cover has flame retardant or flare resistant features. 
     
     
         23 . The mattress as in  claim 16 , wherein the foam pieces comprise polyurethane, urethane, or a combination thereof. 
     
     
         24 . A mattress comprising:
 a core comprising a matrix of foam pieces that are adhesively bonded together by coating the foam pieces with a binder or resin and compressing the foam pieces to a density of between about 4 pounds per cubic foot to about 8 pounds per cubic foot, wherein the core has a thickness in the range from 3 inches to about 8 inches, and an IFD of about 28 to 65, the core having a top surface and a bottom surface, wherein each of the foam pieces ha a size in the range of about 0.25 inch by about 0,25 inch by about 0.25 inch to about 3 inches by about 3 inches by about 1 inch;   a cushion layer coupled to the top surface, wherein the cushion layer comprises air insulated viscofoam, has a density in the range from about 2 pounds per cubic foot to about 6 pounds per cubic foot, a height in the range from 2 inches to about 6 inches and an IFD of about 6 to about 18; and   a base layer coupled to the bottom surface of the core, the base layer comprising a support foam layer having a thickness in the range from 0.25 inch to 2 inches with a density of about 1 pound per cubic foot to about 2 pounds per cubic foot and an IFD of about 28 to about 70.