Claims
- 1. A posturized bedding or seating product, comprising:
a core having a first surface and an oppositely-disposed second surface; an upholstered covering which covers at least one of the core first and second surfaces; and a foam ply positioned between the core and the upholstered covering, the foam ply having a first section which includes latex and a second section which is free of latex, thereby providing the foam ply with different degrees of firmness.
- 2. A posturized foam ply for use in a bedding or seating product, comprising:
a foam ply having a first section which includes latex and a second section which is free of latex, thereby providing the foam ply with different degrees of firmness.
- 3. The posturized foam ply of claim 2 wherein the foam ply is made of polyurethane.
- 4. The posturized foam ply of claim 2 wherein the foam ply has a first surface, an oppositely-disposed second surface, and an interior between the first and second surfaces, the latex of the first section extending into the interior from at least one of the first and second surfaces.
- 5. The posturized foam ply of claim 2 wherein the foam ply has a depth which extends from the first surface to the second surface, the foam ply further having a third section which includes latex, the latex of the third section occupying a greater portion of the depth of the foam ply than the latex of the first section, whereby the firmness of the third section is different from the firmness of the first section.
- 6. The posturized foam ply of claim 5 wherein the latex of the third section does not occupy the entire depth of the foam ply.
- 7. The posturized foam ply of claim 2 wherein the foam ply first section extends in a transverse direction.
- 8. The posturized foam ply of claim 7 wherein the foam ply has a transversely-extending center section, the center section including the first section.
- 9. The posturized foam ply of claim 8 wherein the foam ply has a first side surface and a second side surface, the latex of the first section extending from the first side surface to the second side surface.
- 10. The posturized foam ply of claim 9 further having a third section which includes latex, the latex of the third section extending from the first side surface to the second side surface.
- 11. The posturized foam ply of claim 10 wherein the third section is substantially parallel to the first section.
- 12. The posturized foam ply of claim 11 wherein the center section includes the third section.
- 13. The posturized foam ply of claim 7 wherein the foam ply has a first side surface and a second side surface, the latex of the first section extending between the first side surface and the second side surface.
- 14. The posturized foam ply of claim 13 further having a third section which includes latex, the latex of the third section extending between the first side surface and the second side surface.
- 15. The posturized foam ply of claim 2 wherein the foam ply has a longitudinal dimension and a transverse dimension, the foam ply first section extending in a transverse direction.
- 16. The posturized foam ply of claim 15 wherein the foam ply has a first end surface and a second end surface, the latex of the first section extending between said end surfaces.
- 17. The posturized foam ply of claim 16 further having a third longitudinally extending section which includes latex.
- 18. The posturized foam ply of claim 17 wherein the third section is substantially parallel to the first section.
- 19. The posturized foam ply of claim 18 wherein the foam ply has a first end surface and a second end surface, the latex of the first section extending between the first end surface and the second end surface.
- 20. The posturized foam ply of claim 19 further having a third section which includes latex, the latex of the third section extending between the first end surface and the second end surface.
- 21. A method of making a posturized foam ply for use in a bedding or seating product, the foam ply having a first surface, an oppositely-disposed second surface, an interior between the first and second surfaces, and a depth which extends from the first surface to the second surface, the method comprising the steps of:
applying latex to a first section of one of the first and second surfaces, while maintaining a second section of the one of the first and second surfaces free of latex; moving at least some of the latex from the first section into the interior; and curing the latex, thereby forming a foam ply with different degrees of firmness.
- 22. The method of claim 21 wherein the applying step includes applying the latex as a foamed liquid.
- 23. The method of claim 21 wherein the applying step includes applying the latex to the first section with an application roller.
- 24. The method of claim 23 wherein the application roller includes a circumferential ring having an outer surface, the applying step including applying the latex with the outer surface of the circumferential ring.
- 25. The method of claim 24 wherein the circumferential ring is adjustably positionable along the application roller, whereby an operator may select the location of the first section.
- 26. The method of claim 23 wherein the application roller includes a plurality of circumferential rings, with each ring having an outer surface, the applying step including applying the latex with the outer surface of the plurality of circumferential rings.
- 27. The method of claim 24 wherein each of the plurality of circumferential rings is adjustably positionable along the application roller.
- 28. The method of claim 27 wherein the plurality of circumferential rings includes at least a first ring and a second ring, with a gap existing between the first and second rings, the applying step including applying latex to the first section with the outer surface of the first ring and applying latex to a third section of the one of the first and second surfaces of the foam ply with the outer surface of the second ring.
- 29. The method of claim 27 wherein the plurality of circumferential rings includes at least a first ring and a second ring, the first ring having a cross-sectional outside diameter greater than that of the second ring, the applying step including applying latex to the first section with the outer surface of the first ring and applying latex to a third section of the one of the first and second surfaces of the foam ply with the outer surface of the second ring.
- 30. The method of claim 21 wherein the applying step includes applying the latex to the first section by delivering the latex through a conduit directly down onto the first section.
- 31. The method of claim 30 wherein the conduit includes an outlet which is positioned between first and second guide plates, whereby the width of the first section latex may be controlled.
- 32. The method of claim 23 wherein the moving step includes selecting the speed of the application roller to obtain a desired amount of penetration into the interior.
- 33. The method of claim 23 further including the step of conveying the foam ply in a first direction perpendicular to the axis of the application roller, wherein the moving step includes rotating the application roller in a direction opposite the first direction to obtain a desired amount of penetration into the interior.
- 34. The method of claim 23 further including the step of passing the foam ply through a space between the application roller and a control roller, the space having a height determined by the distance between the application and control rollers, wherein the moving step includes selecting the distance so as to determine a desired amount of penetration into the interior.
- 35. The method of claim 29 wherein the moving step includes using the first ring to achieve a latex penetration into the depth of the foam ply which is greater than the latex penetration achieved by the second ring.
- 36. The method of claim 21 wherein the curing step includes passing the foam ply through a drying oven.
- 37. The method of claim 21 wherein the foam ply is an elongated length of foam ply sufficient in size to form more than one bedding or seating product, the method further including the step of cutting the foam ply.
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of the filing date of Provisional U.S. Patent Application No. 60/189,111 entitled “Posturized Foam Pad with Latex Bands”, filed on Mar. 14, 2000, the entire disclosure of the provisional application being incorporated in its entirety into this application by reference.
Provisional Applications (1)
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Number |
Date |
Country |
|
60189111 |
Mar 2000 |
US |