This invention includes a method to produce a customizable and user-configurable mattress foam core which comprises a plurality of transversely extended foam rods that were cut during the mattress production process. These transversely extended foam rods typically have a cross section of a convex shape, including triangles, squares, rectangles, circles, ovals and hexagons. These transversely extended foam rods can be replaced with foam rods of different firmness, creating more than 10 zones with varying firmness in each zone thus tailoring to the sleeper's needs, adjusting for their differences in height, weight, sleeping position, and comfort preference. Also, these zones together allow the user to configure the mattress for spinal alignment.

The transversely extended replacement foam rods typically have cross sections that are substantially the same shape as the pre-cut foam rods, but may also be of different shape. In one embodiment, the transversely extended replacement foam rods comprises foams of two or more different firmness in the transverse direction, thus allowing the mattress to be customized for multiple users with different sleeping needs.

A foam mattress in which a layer of latex or latex-like foam placed above a layer of memory foam is described. This construction of the mattress provides the contouring pressure relief that a visco-elastic foam provides with a top surface with quick recovery (a latex-like “bounce”) that prevents people from getting “stuck” in the visco-elastic foam and improves the springiness of the mattress. The mattress may also include straps and cinches to aid in transportation of the mattress. The mattress may also include removable covers that aid in keeping the mattress clean.

A furniture spring system includes a lid configured to provide a seating surface. The lid includes a frame having two opposing frame members and a retention member associated with at least one of the two opposing frame members. The furniture spring system further includes a slat extending between the two opposing frame members. The slat includes a plurality of slat portions adjustably coupled to each other, such that a total length of the slat is adjustable.

A mattress comprising a first layer comprising at least one channel extending laterally from a first side of the layer to an opposite side of the layer, and a plurality of foam spheres or hemispheres disposed in each channel. A mattress assembly comprising the mattress and a mattress foundation.

A body support structure comprising one or more gel layers, such as structures comprising a plurality of ridges and a plurality of valleys. Methods of forming the gel layers and body support structures comprising the gel layers. Systems for manufacturing body support structures comprising the gel layers.

This disclosure addresses mattresses. In particular, a mattress that includes a plurality of layers. A foam core of the mattress is constructed to have selected characteristics of support and cushioning, the characteristics varying from zone to zone of the mattress. The foam core includes at least three zones; a first zone corresponding generally to an area that supports the head of a user, a second zone corresponding generally to an area that supports the torso of the user, and a third zone corresponding generally to an area that supports the legs and feet of the user. A top surface of the foam core is formed with a plurality of parallel transverse peaks.

A mattress includes a first end and an opposite second end arranged in a direction of the mattress. The mattress is configured to have a first firmness pattern suitable for side sleepers when the first end is used as a head end and the second end is used as a foot end, and have a second firmness pattern suitable for back sleepers when the first end is used as a foot end and the second end is used as a head end. The mattress has a firmness distribution which is asymmetric about a middle line of the mattress which is perpendicular to the direction.

A body support structure comprising a gel layer comprising at least a first gel lattice, wherein the first gel lattice comprises a plurality of first gel segments, wherein the plurality of first gel segments defines a plurality of first gaps; and a viscoelastic foam layer; wherein the gel layer is directly laminated to the viscoelastic foam layer. Methods of forming the gel layers and body support structures comprising the gel layers. Systems for manufacturing body support structures comprising the gel layers.

Compressible mattress assemblies for bed in a box applications consist of a first polymeric foam layer and a second polymeric foam layer, wherein the first polymeric foam layer has a thickness less than the second polymeric foam layer and has a property and/or a foam material that is different from the second polymeric foam layer. In other embodiments, the compressible mattress assemblies consist of a pocketed microcoil array intermediate the first and second polymeric foam layers.

Compressible mattress assemblies for bed in a box applications generally include a first foam layer and a second foam layer, wherein the first foam layer has a thickness less than the second foam layer and has a property and/or a foam material that is different from the second foam layer. In other embodiments, the compressible mattress assemblies consist of a pocketed microcoil array intermediate the first and second polymeric foam layers.