Fig. 1 discloses a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the subject matter;
Figs. 2A-2B disclose a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the subject matter; and
Fig. 3 discloses a lightweight and fireproof mattress comprising an elevated portion, according to exemplary embodiments of the subject matter.

The following detailed description of embodiments of the invention refers to the accompanying drawings referred to above. Dimensions of components and features shown in the figures are chosen for convenience or clarity of presentation and are not necessarily shown to scale. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

DETAILED DESCRIPTION

Illustrative embodiments of the invention are described below. In the interest of clarity, not all features and/or components of an actual implementation are necessarily described.

The subject matter in the present invention discloses a fireproof lightweight mattress that lacks any materials that emit gasses to the air, as these gasses may damage the user's health. The term "fireproof' used herein depicts a quality of material in which the material resists damages arising from direct fire or high temperatures derived from indirect fire or heat source. An example for direct fire may be a lit cigarette placed on the mattress. An example of indirect heat source may be a heating element such as a radiator or convector touching the mattress.

Fig. 1 discloses a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the subject matter.Fig. 1 discloses a mattress 100 comprising at least afirst foam layer 110. In some embodiments, thefirst foam layer 110 is placed on asupport base 120. Thefirst foam layer 110 has atop surface 111, abottom surface 112, a front side surface 113 arear side surface 114, a firstlateral surface 115 and a secondlateral surface 116. In some embodiments, thefirst foam layer 110 is formed from a single piece of molded lightweight foam. In some embodiments, thetop surface 111 of thefirst foam layer 110 may be designed in a pattern to enhance the comfortability of the mattress. In such cases, the top surface of the first foam layer may be designed, for example, as an egg crate pattern.

Thesupport base 120 is traditionally configured to provide elevation and support for the mattress 100. Thesupport base 120 is typically formed from wood or other material as a solid frame. In some embodiments, thesupport base 120 may be embedded in the mattress 100 as a second layer, located under thefirst foam layer 110. In some embodiments, thefirst foam layer 110 and thesupport base 120 may be formed of the same material yet with a different density. In other embodiments, thefirst foam layer 110 may be placed on the ground/floor as a replacement for thesupport base 120.

In some embodiments, thetop surface 111 of thefirst foam layer 110 may have a different width than thebottom surface 112. In such cases, the firstlateral surface 115 and the secondlateral surface 116 form elongated wedge-shaped notches. In such cases, thesupport base 120 may comprise lateral support extensions for supporting the elongated wedge-shaped notches of thefirst foam layer 110.

In some embodiments, thefirst foam layer 110 is formed from an elastic material. Elasticity, which is an important concept for the aesthetics and firmness of the mattress 100, is expressed by measurements of resilience and permanent set. In some embodiments, thefirst foam layer 110 is formed from a material comprising an average tensile strength in the range of 90-110 kPa and/or average elongation at break in the range of 20%-30% in accordance with ISO 1798.

In some embodiments of the present invention, thefirst foam layer 110 is formed from an open-cell material. In further embodiments, thefirst foam layer 110 is formed from a low-density material. In some embodiments, it is desirable that thefirst foam layer 110 would be lightweight and have a density in the range of 4-10 kg/m3 which makes the mattress significantly lighter compared to regular mattresses.

In some embodiments, the low density of the mattress derives from an open-cell structure of the material from which the mattress is made. Open-cell structure with low density allows air to flow through the material, making the material breathable. It is desirable to prevent infants to lie on a non-breathable foam surface, to prevent sudden infant death syndrome (SIDS) may be caused by the accumulation of carbon dioxide in bedding. Thus, allowing air to flow through thefirst foam layer 110, results in fresh air provided to the user sleeping thereon, which is especially relevant for infants.

In some embodiments, thefirst foam layer 110 is formed from a fire-resistant material. In further embodiments, the fire-resistant material, which thefirst foam layer 110 is formed of, lacks any additional fire redundant materials orconsist of a fire redundant material. In some embodiments, material of thefirst foam layer 110 comprises fire redundant capabilities in accordance with ISO EN 13501-1 and classified as B, s1 and d0. In further embodiments, the fire-resistant material, which thefirst foam layer 110 is formed of, comprises high thermal endurance properties. Specifically, in some embodiments, the thermal endurance of the material forming the first layer is measured in accordance with ISO 2578 (and as defined in ISO 3386-1) as resistant to a heat of 220 °C for 1000 hours.

In further embodiments, the fire-resistant material, which thefirst foam layer 110 is formed of, comprising low thermal conductivity properties. In some cases, the thermal conductivity of the material may be in the range of 0.02- 0.05 W/mK. In more specific cases, the thermal conductivity of the material may be in the range of 0.03-0.04 W/mK. In some embodiments, the thermal conductivity is measured in accordance with the DIN EN 12667 regulation.

In some embodiments, thefirst foam layer 110 is formed from a sound absorbing material. Since many people require a low amount of noise in order to fall asleep, such material would be very beneficial to the formation of a mattress. In some embodiments, the sound absorbing material is formed from an open cell material, comprising a high sound absorption quality. The open cell structure causes the sound waves touching thefirst foam layer 110 to penetrate the cell structure of the material unhindered in contrast to being reflected from the surface of thefirst foam material 110 as an echo. Thus, the sound energy is reduced in the cell structure, giving thefirst foam material 110 an excellent sound absorption capacity. For example, the material may be formed in accordance with regulation ATSM C 426 (U.S.A) as class A. In some embodiments, the thickness of thefirst foam layer 110 may be determined by the desired level of sound absorption. In some embodiments, the sound absorption for a 50 mm thick layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO 10534.

In some embodiments, thefirst foam layer 110 of the mattress 100 may consist of a block of melamine resin, which may be formed as a foam. In further embodiments, the block of melamine foam is formed as an open cell structure. In a non-limiting manner, the block of melamine foam may be the product designated by the trade name "BASOTECT" in the name of BASF, Germany. In further embodiments, thefirst foam layer 110 of the mattress 100 may consist of the product designated by the trade name "BASOTECT UF" in the name of BASF, Germany. The "BASOTECT UF" is characterized by a very high elasticity and by improved fire properties. In further embodiments, the product designated by the trade name "BASOTECT" is either one of: "BASOTECT UF", "BASOTECT UF+", "BASOTECT G" and "BASOTECT G+".

In some embodiments, the entire mattress 100 may be cut out from a single block of material. In some embodiments, the mattress 100 is not limited to a cubic rectangular shape and may be shaped in any form desirable by a user. For example, using a mold, the mattress 100 can be formed to have a shape of a circle fitting on a circular bed, polygonal shapes and the like. For example, in some embodiments, the mattress 100 is shaped to snugly fit inside an infant crib. In such cases, the mattress 100 may be slightly larger than the dimensions of the crib and inserted into the crib when pressed. Thus, the mattress may snugly fit into a crib, despite small variations in the dimensions of the mattress caused by inconsistent manufacturing processes. In such embodiments, the crib comprising such mattress is safer because there is no gap in which an infant's limb could become lodged in.

The width of the mattress 100 may be in the range of 10-50 centimeters, made from a single sheet of lightweight and fireproof material and covered by a covering sheet which is a thin sheet, for example having width in the range of 1.5-20 millimeters, and made of an open-cell structure. The covering layer may be made of cotton. The length of the mattress 100 may be in the range 80-220 centimeters and the breadth of the mattress 100 may be in the range 30-180 centimeters.

Figs. 2A-2B disclose a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the subject matter.Fig. 2A discloses a mattress 200 comprising dual layers. In some embodiments, the mattress 200 comprises afirst foam layer 210 and asecond foam layer 220. In some embodiments, each layer of thefirst foam layer 210 and asecond foam layer 220 may be assembled of a plurality of sublayers. In some embodiments, thefirst foam layer 210 is identical to the first foam layer ofFig. 1 as aforementioned. The shape of thefirst foam layer 210 may vary, and may be rectangular, circular, polygonal or any other shape fitting a user's needs. In some embodiments, thesecond foam layer 220 abuts at least one surface of thefirst foam layer 210. In some embodiments, thesecond foam layer 220 may be formed from a different material from the material of thefirst foam layer 210 and which can provide a better comfort to the user than thefirst foam layer 210. In some embodiments, thesecond foam layer 220 may be formed of viscoelastic material, adapted to distribute the user's weight and to provide a softer layer than thefirst foam layer 210. In some embodiments, thesecond foam layer 220 may coat the entire surface of thefirst foam layer 210.

In some embodiments, the density of thefirst foam layer 210 is greater than the density of thesecond foam layer 220 topping thefirst foam layer 210. In other embodiments, thefirst foam layer 210 is firm and provides sturdy support to thesecond foam layer 220, for a uniform texture across the external surface of the mattress 200. The overall thickness of the mattresses depends on the thicknesses of the

layers

210, 220 with any additional layer of foam that may optionally be added over thesecond foam layer 220.

In some embodiments, as shown inFig. 2B, the mattress 200 comprises three foam layers shaped in accordance with a user's preference. In such cases the mattress 200 comprises abottom layer 230, amiddle layer 232, and atop layer 234.Bottom layer 230 may be formed of regular high-density foam in order to provide stability and support for the mattress 200. In some embodiments, themiddle layer 232 is formed of a viscoelastic material and provides a first cushioning layer for the mattress 200. In some cases, themiddle layer 232 comprises an egg crate pattern on its top surface. Utilizing an egg crate pattern on the top surface provides a softer feel for the user. Thetop layer 234 may be formed as a thin sheet of an open cell material having an especially low density to provide a second cushioning interface for the mattress 200. Thebottom layer 230, themiddle layer 232, and thetop layer 234 may be made of melamine foam. In some other embodiments, thebottom layer 230, themiddle layer 232, and thetop layer 234 may be made of another material that is both fire resistant and of a density lower than 10 kilograms per cubic meter (m3).

Fig. 3 discloses a lightweight and fireproof mattress comprising an elevated portion.Fig. 2 discloses a mattress 300 comprising afirst foam layer 310. The first foam layer has atop surface 311, abottom surface 312 and a front side surface 313 arear surface 314, a firstlateral surface 315 and a secondlateral surface 316. In some embodiments, the first foam layer comprises anelevated foam layer 320 extending from thetop surface 311, and adjacent to therear surface 314 of thefirst foam layer 310. In some embodiments, theelevated foam layer 320 is shaped a single pillow or two adjacent pillows. The pillows are configured to serve as a head rest for providing additional comfort to a user sleeping thereon. In some embodiments, thefirst foam layer 310 and theelevated foam layer 320 are formed from a single block of foam. In some embodiments, theelevated foam layer 320 may be inclined to create a wedge shape.

The claimed invention may also disclose use of a melanin foam in the production of a mattress or another cushioning apparatus. In some exemplary cases, the melanin foam is sliced from a sheet of material according to a predefined shape and covered by cotton or another open-cell structure. The claimed invention also discloses use of melanin foam in the fabrication of a mattress, such that the mattress allows air flow from a bottom surface of the mattress to the top surface of the mattress. The claimed invention also discloses a mattress made of fire resistant material that does not emit gasses, such as bromine. The fire resistance means that the mattress remains solid and firm even when caught by fire and does not change its shape and/or chemical characteristics.

It should be understood that the above description is merely exemplary and that there are various embodiments of the present invention that may be devised, mutatis mutandis, and that the features described in the above-described embodiments, and those not described herein, may be used separately or in any suitable combination; and the invention can be devised in accordance with embodiments not necessarily described above.