Abstract: A foam seating article includes a layer of molded foam surrounding a hollow shell made of hard plastic. A fabric covering encloses the shell and molded foam. The foam seating article can take the form of a chair, stool, sofa, chaise lounge, bench or Ottoman. The hollow shell can be formed using blow molding, injection molding or by capping both ends of a tube with disks. Air pressure inside the airtight hollow shell prevents the shell from collapsing inwards under the weight of an occupant. Alternatively, the hollow shell of the seating article can be accessed through a removable lid. The seating article includes no wood or metal. The layer of molded foam includes sections of different foam types, such as high density (HD) foam, memory foam and latex foam. Molding foam around a hard plastic shell is simpler and less costly than making conventional metal or wood framed furniture.

Abstract: A giant foam building block for children includes an inner core, an outer layer and a barrier skin. The inner core is made of foam or expanded polystyrene having a lower density than the outer layer. The inner core is softer than the outer layer, but both have a hardness less than 20 Shore A. A resin is sprayed onto the inside surface of a mold before the inner core is placed in the mold and the outer layer is molded around the inner core. The outer layer is molded such that an integral skin forms on the inner surface of the mold. The resin attaches to the integral skin and together forms a barrier skin that becomes the outer surface of the block. The block has no covering over the barrier skin. Children are not exposed to the TDI-based foam core which is sealed off by the outer layer.

Abstract: A bed frame includes legs, bars and wooden slats. Each leg has first and second sides that meet each other at an edge. A first slot is disposed on the first side adjacent to the edge, and a second slot is disposed on the second side adjacent to the edge. Each bar has two wedge inserts. A first wedge on a lateral bar fits into the first slot, and a second wedge on a longitudinal bar fits into the second slot. The lateral bar is perpendicular to the leg while the first wedge is lodged in the first slot, and the longitudinal bar is perpendicular to the leg while the second wedge is lodged in the second slot. The first slot and the second slot are disposed between the lateral bar and the longitudinal bar while the first and second wedge inserts are lodged in the first and second slots.

Abstract: A bed frame assembly has diagonal struts that lock leg supports into place using novel locking mechanisms. A leg support is pivotally attached to the bedboard frame, and a slotted bracket is welded to a cross bar of the frame. One end of a diagonal strut is pivotally attached to the leg support, and a bolt with a conical washer and a wing nut is attached to the other end. The strut is attached to the slotted bracket by inserting the bolt into a curved slot in the bracket. The bracket also includes a stopper brace that extends perpendicular to the body of the bracket. A side of the end of the strut pushes against the stopper brace when the conical washer is pressed into the end of the curved slot and the wing nut is tightened. The stopper brace prevents the bolt from sliding out of the curved slot.

Abstract: A bed frame includes legs, lateral and longitudinal bars, and wooden slats. Each leg has two triangular slots, and each bar has two wedge inserts. A first slot opens from a first side of a leg, and a second slot opens from a perpendicular, second side of the leg. A first wedge on a lateral bar fits into the first slot. The lateral bar is perpendicular to the leg while the first wedge is lodged in the first slot. A second wedge on a longitudinal bar fits into the second slot. The longitudinal bar is perpendicular to the leg while the second wedge is lodged in the second slot. Corresponding wedge inserts and triangular slots are identified by the same numerals, which enables the snap assembly of the bed frame. By matching numerals displayed on corresponding wedges and slots, the user can intuitively assemble the bed frame by the numbers.

Abstract: A folding mattress support system replaces a conventional bed frame with rails and the box spring. The mattress support system is lighter, easier to transport, and provides more storage space beneath the mattress. The mattress support system includes bed frame assemblies, central connecting bars, edge attachments, headboard attachments and a bed skirt. Leg supports fold out from the bed frame assemblies, which themselves unfold in the middle. Central connecting bars connect inner side edges of the bed frame assemblies. Plastic edge attachments are attached at outer corners of the bed frame assemblies and hold a bed skirt taut when the frame assemblies are standing on extended leg supports. A mattress is then placed on top of the assembled mattress support system. Optionally, metal edge attachments at the head corners hold both the bed skirt and a headboard. Alternatively, headboard attachments protrude from under the bed skirt and support a headboard.

Abstract: A method of making foam imparts antimicrobial and antiodorant qualities to the foam. Green tea powder is added to the polyol raw materials for making memory foam. The green tea memory foam is used to make pillows, cushions and mattresses. Green tea foam in the top layer of a mattress acts as an antiodorant such that less of the chemical smell of the memory foam is perceived by the user. In addition, the bacteria and mold that would otherwise develop in the moist warmer sleeping environment on memory foam are killed by the green tea additive to the foam. Measurable antimicrobial and antiodorant qualities in the green tea foam are achievable by adding green tea powder constituting less than 2% of the weight of the resulting green tea foam. A neck-support contour pillow is made using memory foam that contains green tea and a green dye.

Abstract: Removable massage modules provide a mattress with a massage function. The mattress is compressed and shipped in a packing box with the massage modules separate from the mattress. The end customer then inserts the massage modules. The mattress has a bottom foam layer with cavities whose walls are perpendicular to the outer surface of the foam layer. Each massage module includes a massage motor encased in molded foam. The molded foam is attached to a foam section with cylindrical holes that pass from an outer side to the molded foam and allow hot air to escape the massage motor. The top and bottom sides of each massage module have the shape formed by the walls of the cavities. The massage modules are connected by power cords to a module controller that receives RF signals from a remote control device. The massage modules can also be inserted into a mattress topper.

Abstract: A collapsible mattress support for a box spring includes hinges on opposite sides of a middle cross bar. First and second side bars are pivotally attached to one hinge, and third and fourth side bars are pivotally attached to the other hinge. Each of the bars rotates about parallel axes that are orthogonal to the hinges. The four side bars each has a common width. A first distance between the axes about which the first and second bars rotate equals twice the common width of the bars plus a second distance between the axes about which the third and fourth bars rotate. In one embodiment, the cross bars are extendable. The components of the mattress support for Queen, California King and Eastern King sized mattresses fit in a packing box whose length is no greater than 45 inches and whose width and height are each no more than 7 inches.

Abstract: An assemblable mattress support can be shipped with all of its components compactly packed into the headboard. The mattress support includes a foldable longitudinal bar, a lateral bar, side panels, wooden slats, block legs and a footboard, all of which fit inside a compartment in the headboard. In an assembled state of the mattress support, a first connector at one end of the longitudinal bar attaches to a third connector on the outside of the headboard. A second connector at the other end of the longitudinal bar attaches to a fourth connector on the footboard. The middle of the lateral bar connects to the middle of the longitudinal bar. The block legs are attached to the bottom sides of the headboard and footboard. The slats are attached to one another by fabric ribbons and are placed in parallel over the longitudinal bar and support ledges on the side panels.

Abstract: A foam seating article includes an outer foam layer molded around an inner core of molded foam or expanded polystyrene that includes a lumbar support protrusion. The lumbar support protrusion has a convex outer surface disposed inside the seat back area of the outer foam layer and that is not visible on the outer contour of the seat back area. The inner core is made from polyurethane polyol and methylene diphenyl diisocyanate (MDI) and has a hardness greater than 25 Shore A and a density less than two pounds per cubic foot. The polymer material of the inner core has a hardness greater than that of the outer foam. The outer layer of molded foam is high density (HD) foam, memory foam or latex foam. A fabric covering encloses the inner core and molded outer foam layer. The foam seating article can be a chair, sofa, chaise lounge or bench.

Abstract: A foam seating article includes a layer of molded foam surrounding a hollow shell made of hard plastic. A fabric covering encloses the shell and molded foam. The foam seating article can take the form of a chair, stool, sofa, chaise lounge, bench or Ottoman. The hollow shell can be formed using blow molding, injection molding or by capping both ends of a tube with disks. Air pressure inside the airtight hollow shell prevents the shell from collapsing inwards under the weight of an occupant. Alternatively, the hollow shell of the seating article can be accessed through a removable lid. The seating article includes no wood or metal. The layer of molded foam includes sections of different foam types, such as high density (HD) foam, memory foam and latex foam. Molding foam around a hard plastic shell is simpler and less costly than making conventional metal or wood framed furniture.

Abstract: A foam seating article includes an outer layer of molded foam surrounding a solid inner core of molded foam or expanded polystyrene. The rigid foam of the inner core is made from polyurethane polyol and methylene diphenyl diisocyanate (MDI). The inner core has a hardness greater than 25 Shore A and a density less than two pounds per cubic foot. The polymer material of the solid core has a hardness that is greater than that of the outer foam. The outer layer of molded foam is high density (HD) foam, memory foam or latex foam. A fabric covering encloses the inner core and molded outer foam layer. The foam seating article can be a chair, stool, sofa, chaise lounge, bench or Ottoman. The seating article includes no wood or metal. Molding foam around a solid inner core is simpler and less costly than making conventional metal or wood framed furniture.

Abstract: A method of making foam imparts antimicrobial and antiodorant qualities to the foam. Green tea powder is added to the polyol raw materials for making memory foam. The green tea memory foam is used to make pillows, cushions and mattresses. Green tea foam in the top layer of a mattress acts as an antiodorant such that less of the chemical smell of the memory foam is perceived by the user. In addition, the bacteria and mold that would otherwise develop in the moist warmer sleeping environment on memory foam are killed by the green tea additive to the foam. Measurable antimicrobial and antiodorant qualities in the green tea foam are achievable by adding green tea powder constituting less than 2% of the weight of the resulting green tea foam. A neck-support contour pillow is made using memory foam that contains green tea and a green dye.

Abstract: A folding mattress support system replaces a conventional bed frame with rails and the box spring. The mattress support system is lighter, easier to transport, and provides more storage space beneath the mattress. The mattress support system includes bed frame assemblies, central connecting bars, edge attachments, headboard attachments and a bed skirt. Leg supports fold out from the bed frame assemblies, which themselves unfold in the middle. Central connecting bars connect inner side edges of the bed frame assemblies. Plastic edge attachments are attached at outer corners of the bed frame assemblies and hold a bed skirt taut when the frame assemblies are standing on extended leg supports. A mattress is then placed on top of the assembled mattress support system. Optionally, metal edge attachments at the head corners hold both the bed skirt and a headboard. Alternatively, headboard attachments protrude from under the bed skirt and support a headboard.