Claims:We claim:

1. An improved, low-cost, low-weight mattress (100) made of shredded foam, said mattress comprising:

(a) a hollow casing (110) of a predefined size, shape and thickness and made of high-strength fabric;

(b) shredded foam pieces/strips (120) of predefined size filled in said casing (110);

wherein said casing (110) is filled with a predetermined volume of said shredded foam pieces/strips (120) to obtain the targeted size/shape/density/weight of said mattress.

2. The mattress as claimed in claim 1, wherein said casing (110) is filled with foam pieces/strips (120) in a predefined density and formed into a predefined shape and size by means of tucks (130) passed therethrough in a predetermined pattern to obtain a predefined tufting (140).

3. The mattress as claimed in claim 1, wherein said casing is made of automotive grade fabric.

4. The mattress as claimed in claim 1, wherein said mattress is filled with shredded PU foam.

5. The mattress as claimed in claim 4, wherein said mattress is filled with recycled shredded PU foam.

6. The mattress as claimed in claim 4, wherein said mattress is filled with PU foam obtained as left-over or discarded material from other applications.
7. The mattress as claimed in claim 1, wherein said casing (110) is made of automotive grade fabric and filled with foam pieces/strips (120) in a predefined density and formed into a predefined shape and size by means of tucks (130) passed therethrough in a predetermined pattern to obtain a predefined tufting (140) thereon.

8. The mattress as claimed in claim 1, wherein said mattress is filled with shredded PU foam.

9. The mattress as claimed in claim 8, wherein said mattress is filled with recycled shredded PU foam obtained as left-over or discarded material from other applications.

10. The mattress as claimed in claim 1 to 9, wherein said mattress is vacuum compressed to reduce the size/volume thereof for facilitating an economic storage and/or transportation thereof.

Dated this 20th day of February 2020.

Digitally Signed.

(SANJAY KESHARWANI)
APPLICANT’S PATENT AGENT
REGN. NO. IN/PA-2043. , Description:FIELD OF INVENTION

The present invention relates to an improved mattress made of shredded foam. In particular, the present invention relates to an improved mattress filled with shredded foam. More particularly, the present invention relates to a low-cost and low-weight mattress made of a casing filled with shredded foam.

BACKGROUND OF THE INVENTION

Indian mattress market consists of organized market and unorganized market. Normally, the organized market consists of manufacturers making mattresses filled with foam sheets as well as cotton with or without spring support. While the unorganized market consists of local manufacturers using cotton fibers compacted to desired densities manually or by carding/filling/compacting.

Although, unorganized sector’s mattresses still dominate current Indian market over organized sector’s mattresses by a ratio of 65:35. This is particularly due the low-cost of cotton mattresses, which are available under INR 2000. However, during last about 3 decades, modern mattresses have replaced cotton mattresses in a big way, especially within urban populace.
An advantage of these foam mattresses is that these can be made of foam sheets of various sizes, i.e. length, width, thickness and different densities and/or stitched in casings made of tough, stain-free fabric.

The foam used in mattresses may generally use PU foam or more recently mattress types use memory foam. However, these mattresses are still high in weight and cost too high because of use of virgin foam sheets. Moreover, the fabric used is not of sufficient strength, deteriorates/tears off easily and fades very quickly and thus is not durable enough.
It is also not bugs/insect repellent and is prone to be stained and dusty easily over prolonged use. The presently used mattresses are also not odour-free.

Therefore, there is an existing need for providing an improved mattress configuration, which is low-cost, low-weight, sufficiently strong and durable. It should also be resistant to bugs/insects, odour-free and stain-resistant. There is also needed an improved mattress which can easily be wiped of dust and/or washed/dried from the hygiene point of view.

This will also help in the organized sector to gain substantial market share over the unorganized cotton mattress market.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide an improved low-cost mattress using shredded foam.

Another object of the present invention is to provide an improved low-weight mattress using shredded foam.

Still another object of the present invention is to provide an improved mattress, made of shredded foam, made strong and durable over prolonged use.

Yet another object of the present invention is to provide an improved mattress which is manufactured sustainably using discarded/recycled foam.

A further object of the present invention is to provide an improved mattress which is substantially stain-resistant, easy to wipe-off dust therefrom, and can be easily washed and dried.

A still further object of the present invention is to provide an improved mattress which is substantially bugs/insects repellent.

A yet further object of the present invention is to provide an improved mattress which reduces the inventory cost by using a single type of shredded foam.

One object of the present invention is to provide an improved mattress which is easy to be made in different sizes, shapes and/or densities by using the same shredded foams.

One more object of the present invention is to provide an improved mattress which can be made using the shredded foams and packed by vacuum compression for transportation to users/sellers/stores.

These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided an improved, low-cost, low-weight mattress made of shredded foam, the mattress comprising:

(a) a hollow casing of a predefined size, shape and thickness and made of high-strength fabric;

(b) shredded foam pieces/strips of predefined size filled in the casing;

wherein the casing is filled with a predetermined volume of the shredded foam pieces/strips to obtain the targeted size/shape/density/weight of the mattress.

Typically, the casing is filled with foam pieces/strips in a predefined density and formed into a predefined shape and size by means of tucks passed therethrough in a predetermined pattern to obtain a predefined tufting.

Typically, the casing is made of automotive grade fabric.

Typically, the mattress is filled with shredded PU foam.

Typically, the mattress is filled with recycled shredded PU foam.

Typically, the mattress is filled with PU foam obtained as left-over or discarded material from other applications.

Typically, the casing is made of automotive grade fabric and filled with foam pieces/strips in a predefined density and formed into a predefined shape and size by means of tucks passed therethrough in a predetermined pattern to obtain a predefined tufting thereon.

Typically, the mattress is filled with shredded PU foam.

Typically, the mattress is filled with recycled shredded PU foam obtained as left-over or discarded material from other applications.

Typically, the mattress is vacuum compressed to reduce the size/volume thereof for facilitating an economic storage and/or transportation thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described in the following with reference to the accompanying drawings.

Figure 1 shows a perspective view of the shredded foam mattress made in accordance with the present invention.

Figure 2 shows the top view of the mattress of Figure 1 indicating important features thereof.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, an improved and low-cost mattress made of recycled/discarded memory foam pieces shredded and configured in accordance with the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention.

Figure 1 shows a perspective view of the shredded foam mattress 100 made in accordance with the present invention and having a length L, width W, and thickness H respectively. It includes a casing 110 filled with shredded foam 120 and preferably packed under vacuum compression for reducing the volume thereof for saving transportation and storage costs.

Figure 2 shows the top view of the mattress 100 of Figure 1 indicating important features thereof. It includes a casing 110 filled with shredded foam 120 and stitched by tucks 130 at predetermined distances and in predefined patterns of tufting 140 to obtain a particular targeted cushioning effect thereon. It finished mattress 100 is preferably packed under vacuum compression for reducing the volume thereof for saving transportation and storage costs.
The mattress 100 can be made in any targeted size and density for imparting optimum comfort to the users thereof at much lower costs due to its low-weight and additional gaps between the shredded foam filled therein provides additional bounce thereon, which also reduces the required density of shredded foam to be used as compared to conventional PU foam block.

The shredded foam filled therein also provides enhanced comfort to the users by more easily taking the shape of the user’s body.

Moreover, this mattress is also made stain resistant as per standard AATCC 130. Since it is made of a 100% synthetic material, e.g. shredded foam, it is substantially more resistant to insects/bugs as compared to the existing foam mattresses. The textile structure of the automotive grade fabric used therein mattress also makes intrusion of common house insects in this mattress.

This shredded foam mattress is stain-resistant, odour-free, and facilitates easy dust wiping therefrom and/or easy washing thereof. The inventive mattress can also be easily washed and sun-dried without affecting the appearance and performance thereof.

It can be manufactured more sustainably by using foams which may be of serviceable quality, even those obtained as left-over from other applications. It can be made in different forms/shapes/sizes and in different densities to help in reducing the inventory to be maintained using just the shredded foam.

In accordance with the present invention, the mattress casing is usually made of automotive grade fabric and is pre-stitched/formed according to the targeted shape, size, density thereof.

This mattress has also successfully passed the mandatory tests for different desirable properties like, anti-sagging, tear-resistance, light fastness, crumpling resistance as well as dirt and dust adhesion.

DESCRIPTION OF THE INVENTION

In accordance with the present invention, the present invention provides an improved, low-cost, low-weight, strong and durable mattress made of foam pieces.

This improved mattress is stain-resistant, odour-free, and facilitates easy dust wiping therefrom and/or easy washing thereof.

The mattress provided in accordance with the present invention is also manufactured more sustainably by using foams which may be of serviceable quality obtained from other applications.

It can be made in different forms/shapes/sizes and in different densities by using a single type of shredded foam pieces, thus reduces the inventory to be maintained for different size, thickness and densities of foam sheets to a single type of shredded foam pieces.

The mattress made in accordance with the present invention is made by filling the shredded foam pieces in a casing made of automotive grade casing pre-formed according to the targeted shape/size/density thereof.

This automotive grade casing fabric used for making the improved mattress imparts it highly desirable quality of bug/insect repellency and/or also makes it odour-free over prolonged use thereof.

This automotive grade casing fabric used for such mattresses also ensures easy dusting and/or washing thereof.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The improved and low-cost mattress made of recycled/discarded memory foam pieces shredded and configured in accordance with the present invention offers the following advantages:

• Lower cost by using shredded foam pieces than conventional expensive foam sheets.

• Low-weight due to use of shredded foam pieces.

• Strong and durable over prolonged use.

• Sustainably manufactured by using shredded foam pieces.

• Substantially stain-resistant, easy to wipe-off dust therefrom.

• Easy washing and sun-drying.

• Substantially bugs/insects repellent.

• Reduces inventory cost by using only shredded foam pieces.

• Reduces transportation and storage cost with vacuum compressed packing.
• Easily made in different sizes/shapes/densities from the same type of shredded foam pieces.

• More comfortable due to easy adjustment of shredded foam according to user-body shape.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to imply including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.