Method of making mattress core with individual foam columns and no springs.
First Claim
1. A method of making a mattress, where the method comprises the steps of obtaining a mattress forming table, where the mattress forming table has two or more molds, where each of the two or more molds has a separate heating control and a separate cooling control, where a computer controls the separate heating control and the separate cooling control for each mold, and where the resulting mattress comprises a mattress core, comprising a top edge, a bottom edge, two side edges, where the top edge, bottom edge and side edges are joined at approximately a 90 degree angle to one another, a mattress bottom, and a mattress main body, where the mattress main body is bounded by the top edge, the bottom edge and the two side edges, and where the mattress body additionally comprises at least two columns, where the at least two columns have a head and a foot, where the foot is a continuous piece of foam extending the entire mattress body, and the head is bounded by air on at least 75% of its diameter and extends vertically from the mattress body, and additionally comprising a cleaning and preparation procedure that ensure that the mattress forming table is adequately prepared to smoothly and efficiently produce one or more mattresses.
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Abstract
This invention is a mattress core that is manufactured as a single unit. It is made up of individual cones that have different configurations resulting in different densities at different portions of the mattress. There are three main ways to accomplishing this goal: columns of different sizes and shapes, columns with different hole diameters, and columns with different density foam used to create them. A key advantage of this invention is that it is a single mattress made from a single mold and does not require multiple parts to be put together.
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20 Claims
- 1. A method of making a mattress, where the method comprises the steps of obtaining a mattress forming table, where the mattress forming table has two or more molds, where each of the two or more molds has a separate heating control and a separate cooling control, where a computer controls the separate heating control and the separate cooling control for each mold, and where the resulting mattress comprises a mattress core, comprising a top edge, a bottom edge, two side edges, where the top edge, bottom edge and side edges are joined at approximately a 90 degree angle to one another, a mattress bottom, and a mattress main body, where the mattress main body is bounded by the top edge, the bottom edge and the two side edges, and where the mattress body additionally comprises at least two columns, where the at least two columns have a head and a foot, where the foot is a continuous piece of foam extending the entire mattress body, and the head is bounded by air on at least 75% of its diameter and extends vertically from the mattress body, and additionally comprising a cleaning and preparation procedure that ensure that the mattress forming table is adequately prepared to smoothly and efficiently produce one or more mattresses.
Specification