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1. (WO2001034356) QUILTED FOAM PAD AND METHOD OF MAKING SAME FROM SCRAP FOAM

Pub. No.:    WO/2001/034356    International Application No.:    PCT/US2000/010615
Publication Date: Fri May 18 01:59:59 CEST 2001 International Filing Date: Fri Apr 21 01:59:59 CEST 2000
IPC: A47C 27/14
B32B 5/32
B32B 7/08
B68G 7/00
Applicants: RESIDUE REGENCY PAD CORP.
LIEBLEIN, Kenneth
Inventors: LIEBLEIN, Kenneth
Title: QUILTED FOAM PAD AND METHOD OF MAKING SAME FROM SCRAP FOAM
Abstract:
A quilted pad (120) is made by chopping post-industrial scrap foam (12) into particles (100) and then feeding them into a foam layout machine (60). The chopped foam particles (100) are deposited across a fabric bottom carrier sheet (101) in a uniform layer (102). At the end of the layout machine (60), a top fabric sheet (103) is placed over the foam layer (102), and then quilts a geometric pattern (110) of pockets which separate and secure the foam particles (100). The foam particle sheet (102) is then cut into panels (81) and the panel (81) edges are finished, creating a low cost but highly functional and attractive pad (120) that can be used as a cushioning pad internal to a conventional bed mattress, as padding in the manufacture of futons, as a low cost mattresses for camping, for use in emergency and homeless shelters or as after-market padding to add to a conventional bed mattress for extra comfort.