Lightweight and fireproof mattress

Abstract

A mattress having a lightweight first foam layer including a top surface and a bottom surface, where the first foam layer is formed from a single piece of molded foam, and where the lightweight first foam layer is formed at least partly from melamine resin.

What is claimed is: 
     
         1 . A mattress, comprising:
 a lightweight first foam layer comprising a top surface and a bottom surface, wherein the first foam layer is formed from a single piece of molded foam,   wherein said lightweight first foam layer is formed at least partly from melamine resin.   
     
     
         2 . The mattress of  claim 1 , wherein the top surface of the first foam layer is shaped as an egg crate pattern. 
     
     
         3 . The mattress of  claim 1 , wherein the mattress defines an elevated portion on the top surface and adjacent to a rear surface of the first foam layer, and wherein the elevated portion forms a pillow. 
     
     
         4 . The mattress of  claim 3 , wherein the elevated portion is designed with an inclination to form elongated wedge-shaped notches. 
     
     
         5 . The mattress of  claim 1 , wherein the density of the first foam layer is in a range of 4-10 kg/m 3 . 
     
     
         6 . The mattress of  claim 1 , wherein the mattress lacks fire retardant additives. 
     
     
         7 . The mattress of  claim 1 , wherein the first foam layer is partly formed of a polyurethane foam. 
     
     
         8 . The mattress of  claim 1 , wherein the first foam layer is formed solely from/composed of a melamine resin. 
     
     
         9 . The mattress of  claim 8 , wherein the melamine resin is a product designated by the trade name “BASOTECT” in the name of BASF, Germany. 
     
     
         10 . The mattress of  claim 9 , wherein the product designated by the trade name “BASOTECT UF” is either one of: “BASOTECT UF”, “BASOTECT UF+”, “BASOTECT G” and “BASOTECT G+”. 
     
     
         11 . The mattress of  claim 1 , wherein the first foam layer is formed from a material that is classified as fireproof in accordance with ISO EN 13501-1 in categories B, s1 and d0. 
     
     
         12 . The mattress of  claim 1 , wherein the first foam layer is formed from a material that is classified as fireproof in accordance with ISO EN 13501-1 in categories B, s1 and d0. 
     
     
         13 . The mattress of  claim 1 , wherein the first foam layer comprises low thermal conductivity properties, wherein low the thermal conductivity is measured in the range of 0.02-0.05 W/mK. 
     
     
         14 . The mattress of  claim 1 , wherein the first foam layer is formed from a material comprising a tensile strength in the range of 90-110 kPa and average elongation at break in the range of 20%-30% in accordance with ISO 1798. 
     
     
         15 . The mattress of  claim 1 , wherein the first foam layer top surface and the first foam layer bottom surface have different widths. 
     
     
         16 . The mattress of  claim 1 , wherein the first foam layer is formed with an open cell structure. 
     
     
         17 . The mattress of  claim 1 , further comprising a covering layer configured to cover the first foam layer, said covering layer is made of a fire-resistant material. 
     
     
         18 . The mattress of  claim 1 , wherein the mattress comprising a second layer, abutting at least one of the first foam layer surfaces, and wherein the second layer is formed from a viscoelastic material. 
     
     
         19 . The mattress of  claim 18 , wherein the second layer abutting the top surface of the material. 
     
     
         20 . The mattress of  claim 1 , wherein the first foam layer is formed from a material providing more than 25 N under an indentation hardness test. 
     
     
         21 . The mattress of  claim 1 , wherein the sound absorption for a 50 mm thick first layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO 10534.