Foamex L.p.

Foamex Innovations Operating Company

Other

Jose D Contreras

Vincenzo A Bonaddio

Denys Denney

Arthur C Barr

Beat B Niederoest, Jr

Stephen C Warren

Lewis Sturgill

Kerry Lynn McCabe

Apparatus and methods for cutting compressible cellular polymers such as polyurethane foam, are characterized by a first die roller and a pressure roller, wherein both rollers define raised portions separated by recesses or depressions, and the raised portions on the first die roller register with the recesses of the pressure roller at a nip formed between the rollers. Portions of the polymer material extruded into the spaces between the raised portions of the first die roller are cut away, such that the cut product conforms substantially to the surface geometry of the first die roller, and the depth of cut is greater than with prior rotary cutting methods.

Surface shaping of compressible cellular polymers with continuous rotary method

A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft/ft/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress.

Mattress adapted for supporting heavy weight persons

A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface. The cut portions then are removed leaving a profile-cut surface with cut-out portions corresponding in pattern and shape to the recesses provided on the moving patterned platform. Depending upon the compression factor of the material, the cut-out portions will substantially correspond in depth to the recesses provided on the moving patterned platform.

Method of cutting a cellular polymer surface with a continous platform

The invention provides a pillow to support a user's head and neck and a portion of his upper body during sleep or resting. The pillow has a generally planar lower support surface and an upper support surface. A rear lobe and a front lobe are separated by a trough on the support surface. A wedge portion depends downwardly from the front lobe toward the front edge of the pillow. The wedge portion and front lobe together function to support the neck and a portion of the user's upper body when his head is held within and is supported by the trough.

Contoured pillow

Mattress topper or pad

Synthetic foam compressed between a pattern roller and a smooth compression roller is driven against a cutting edge closely adjacent and tangent to the pattern surface but spaced from the compression roller to reproduce a three dimensional pattern roller surface on the foam sheet. Three dimensional patterns of arbitrary geometries including sharp edged, flat surfaced geometric solids can be reproduced on a foam surface.

Apparatus for three dimensional surface shaping of synthetic foam

A foam mattress pad of adjustable size has an initial predetermined length, width and thickness. The pad is provided with punched areas or holes, preferably in rows or columns forming a guide for cutting or tearing away strips of foam material to decrease the size dimensions of the pad. In a preferred embodiment, the holes are formed in rows or columns in the base of troughs between peaks of a convoluted surface of the mattress pad. The holes in the troughs may be separately punched or cut before or after the foam is convoluted. Preferably, the holes in the troughs are formed as the foam is cut by the band knife blade during one pass between convolute rollers. Longer projecting fingers are applied to some portions of the convolute roller to achieve the holes in the bases of the troughs. The mattress pad so formed may be sold in a large size, such as queen or king, and reduced by the consumer to a desired smaller size, such as twin or full, by tearing or cutting away strips of foam material along the punched area guide.

Mattress pad of adjustable size

Seat

Pillow

A mattress border construction includes a foam rail sleeve encasing a single row of coil springs so that the top, bottom and sides of the row of springs are surrounded by foam. The row of coil springs is inserted into the hollow inner core of a foam rail sleeve. Preferably, a longitudinal slit is cut through the side wall of the foam rail sleeve to facilitate insertion of the row of springs into the inner core of the foam rail sleeve. The slit is then sealed closed with a suitable adhesive. Several border assemblies are positioned around a center body-supporting mattress portion, which may be a foam, spring coil or water mattress. The mattress center sections and borders may be joined together with adhesive, and are wrapped in a sheet of fabric or other covering material that is staple fastened to the core components. A welt cord may then be stitched around the border edges at top and bottom of the mattress. The combination of springs surrounded by foam has better side to side stability and body support than prior border constructions.

Growing community of inventors

Fontana, CA, United States of America

Jose D Contreras