FOOD-GRADE POLYETHYLENE MATTRESS
A non-toxic mattress and method of constructing the mattress having a reduced toxicity has an outer layer of a material selected from the group comprising polyethylene and polylactic acid film. Also, a mattress cover for covering the outer layer of the mattress can also be constructed from a material selected from the same group of materials. The polyethylene and polylactic acid films are non-toxic materials which reduce adverse human allergenic reactions or exposure to potentially harmful chemicals used in the mattress construction.
1 . A mattress comprising:
a Food Grade Low Density Polyethylene cover;
an outer material in contact with the Food Grade Low Density Polyethylene cover; and
an inner material in contact with the outer material.
2 . The mattress of claim 1 , wherein the Food Grade Low Density Polyethylene has a density of 0.85 to 1.00 grams per cubic centimeter; a maximum extractable fraction (expressed as percent by weight of the polymer) in N-Hexane at specified temperatures is 5.5% at 50 Degrees Centigrade (Deg C); and a maximum extractable fraction (expressed as percent by weight of the polymer) in Xylene at specified temperatures is 11.3% at 25 Deg C.
3 . The mattress of claim 1 , wherein the Food Grade Low Density Polyethylene cover is heat fused to the outer material.
4 . The mattress of claim 3 , wherein the outer material is constructed of cotton, polyester, polypropylene, polylactic acid, wool, polyurethane, and combinations thereof.
5 . The mattress of claim 1 , wherein the mattress comprises an additional layer composed of a fabric flame barrier and flame retardant.
6 . The mattress of claim 1 , wherein the inner material is constructed of a material selected from the group consisting of cotton batting, Food Grade Low Density Polyethylene, polyethylene, metal, polyester, polyurethane, and polylactic acid to providing vibration dampening, insulation, and cushioning.
7 . The mattress of claim 1 , wherein the inner material is constructed of a support material that maintains a shape of the mattress.
8 . A method to prepare a mattress, comprising the steps of:
forming a Food Grade Low Density Polyethylene cover;
forming an outer layer contacting the Food Grade Low Density Polyethylene cover; and
forming an inner material contacting the outer material.
9 . The method of claim 8 , wherein the Food Grade Low Density Polyethylene has a density of 0.85 to 1.00 grams per cubic centimeter; a maximum extractable fraction (expressed as percent by weight of the polymer) in N-Hexane at specified temperatures is 5.5% at 50 Degrees Centigrade (Deg C); and a maximum extractable fraction (expressed as percent by weight of the polymer) in Xylene at specified temperatures is 11.3% at 25 Deg C.
10 . The method of claim 8 , wherein the Food Grade Low Density Polyethylene cover is heat fused to the outer material.
11 . The method of claim 10 , wherein the outer material is constructed of cotton, polyester, polypropylene, polylactic acid, wool, polyurethane, and combinations thereof.
12 . The method of claim 8 , wherein the mattress comprises an additional layer composed of a fabric flame barrier and flame retardant.
13 . The method of claim 8 , wherein the inner material is constructed of a material selected from the group consisting of cotton batting, Food Grade Low Density Polyethylene, polyethylene, metal, polyester, polyurethane, and polylactic acid to providing vibration dampening, insulation, and cushioning.
14 . The method of claim 8 , wherein the inner material is constructed of a support material that maintains a shape of the mattress.
15 . The mattress of claim 1 , wherein the Food Grade Low Density Polyethylene cover can be in close proximity to or in contact with a user's skin.
16 . The method of claim 8 , wherein the Food Grade Low Density Polyethylene cover can be in close proximity to or in contact with a user's skin.
17 . The mattress of claim 1 , wherein the mattress is sized to fit a basinet, crib, cradle, or bed.
18 . The method of claim 8 , wherein the mattress is sized to fit a basinet, crib, cradle, or bed.