A computer-shaped motion bed system includes a mattress having embedded therein an array of disks, a sensor array for sensing body position on the mattress, an array of actuators, and an array of connectors for connecting each of a plurality of the disks embedded in the mattress to each of a plurality of the actuators. The system includes a controller having a processor coupled to a data store and in communication with the array of actuators, and programmed, upon receiving signals from the sensor array, to cause the a subset of the array of actuators to pull on a subset of the array of connectors, thereby pulling on a subset of the array of disks embedded in the mattress, so as to alter contours of a surface of the mattress, whereby the mattress is caused to increase comfort of a user, match contours of the user's body, or better support the user's body.

A computer-shaped motion bed system includes a mattress having embedded therein an array of disks, a sensor array for sensing body position on the mattress, an array of actuators, and an array of connectors for connecting each of a plurality of the disks embedded in the mattress to each of a plurality of the actuators. The system includes a controller having a processor coupled to a data store and in communication with the array of actuators, and programmed, upon receiving signals from the sensor array, to cause the a subset of the array of actuators to pull on a subset of the array of connectors, thereby pulling on a subset of the array of disks embedded in the mattress, so as to alter contours of a surface of the mattress, whereby the mattress is caused to increase comfort of a user, match contours of the user's body, or better support the user's body.

A long synthetic resin foam body composed of a thermoplastic resin expanded beads-molded substrate and a frame having displacement regulating sections provided at both ends in the longitudinal or lateral direction of the substrate and a connecting section that connects the displacement regulating sections to each other. The substrate has at least one joint forming portion that divides the substrate in a direction intersecting the connecting section into two or more substrate parts. The joint forming portion has a joint that connects the adjacent two substrate parts to each other and is deformable to permit a relative displacement between the adjacent two substrate parts when the substrate contracts or expands.

An apparatus and method are provided for a sofa seat cushion comprising a cushion core including a multiplicity of pocketed springs enclosed within an upholstery foam envelope. The pocketed springs are positioned side by side in a spring layer arrangement and are independently operable. A memory foam layer positioned above the upholstery foam envelope comprises a material capable of molding to a person's body sitting on the sofa seat cushion and then quickly returning to an original shape once the person leaves the sofa seat cushion. The memory foam layer comprises a gel-infused visco-elastic memory foam with a polyethylene terephthalate layer positioned there above. Directly below the upholstery foam envelope is an upholstery-grade polyurethane foam layer with a polyethylene terephthalate layer positioned directly thereunder. An exterior upholstery surrounding the cushion core provides a plush seating surface.

An apparatus and method are provided for a sofa seat cushion comprising a cushion core including a multiplicity of pocketed springs enclosed within an upholstery foam envelope. The pocketed springs are positioned side by side in a spring layer arrangement and are independently operable. A memory foam layer positioned above the upholstery foam envelope comprises a material capable of molding to a person's body sitting on the sofa seat cushion and then quickly returning to an original shape once the person leaves the sofa seat cushion. The memory foam layer comprises a gel-infused visco-elastic memory foam with a polyethylene terephthalate layer positioned there above. Directly below the upholstery foam envelope is an upholstery-grade polyurethane foam layer with a polyethylene terephthalate layer positioned directly thereunder. An exterior upholstery surrounding the cushion core provides a plush seating surface.

An apparatus and method are provided for a sofa seat cushion comprising a cushion core including a multiplicity of pocketed springs enclosed within an upholstery foam envelope. The pocketed springs are positioned side by side in a spring layer arrangement and are independently operable. A memory foam layer positioned above the upholstery foam envelope comprises a material capable of molding to a person's body sitting on the sofa seat cushion and then quickly returning to an original shape once the person leaves the sofa seat cushion. The memory foam layer comprises a gel-infused visco-elastic memory foam with a polyethylene terephthalate layer positioned there above. Directly below the upholstery foam envelope is an upholstery-grade polyurethane foam layer with a polyethylene terephthalate layer positioned directly thereunder. An exterior upholstery surrounding the cushion core provides a plush seating surface.

An apparatus and method are provided for a sofa seat cushion comprising a cushion core including a multiplicity of pocketed springs enclosed within an upholstery foam envelope. The pocketed springs are positioned side by side in a spring layer arrangement and are independently operable. A memory foam layer positioned above the upholstery foam envelope comprises a material capable of molding to a person's body sitting on the sofa seat cushion and then quickly returning to an original shape once the person leaves the sofa seat cushion. The memory foam layer comprises a gel-infused visco-elastic memory foam with a polyethylene terephthalate layer positioned there above. Directly below the upholstery foam envelope is an upholstery-grade polyurethane foam layer with a polyethylene terephthalate layer positioned directly thereunder. An exterior upholstery surrounding the cushion core provides a plush seating surface.

A method for producing a vehicle seat member (30) in which a frame member (20) having protrusions (23, 25) is integrally molded to a foamed resin molded body (10) with high dimensional accuracy is provided. The method comprises an in-mold foam molding step of placing the frame member (20) in a mold (100), packing prefoamed resin particles, and molding the foamed resin molded body (10) by in-mold foam molding; and a demolding step of removing the mold (100) to obtain the vehicle seat member (30), wherein in the in-mold foam molding step, the foamed resin molded body (10) is molded so that (BA)/B is 13/1000 or less, wherein A is an outer dimension of the foamed resin molded body (10) in the vehicle seat member (30) obtained by the demolding step and B is an inner dimension of the mold (100) corresponding to the outer dimension.

An endoskeleton elastomer that variably impacts the mattress firmness head-to-toe is described. The elastomer fills voids cut into the foam using contour cutting or spherical cap-shaped cutouts. The elastomer is poured as a hot liquid into the voids, and cools to a solid elastomer. The specific incarnation involves the creation of a set of parallel inclusions at the center of the mattress or a set of spherical cap-shaped cutouts that help prop up the hip area to maintain proper spinal alignment by firming the center of the mattress. The depth, width, shape, spacing, elastomer durometer, and location (both head-to-toe and depth in the mattress) may be varied to impact firmness in any desired manner. The mattress may also include a series of horizontal-oriented cutouts that are cut into various portions of the mattress layers. These cutouts may extend along the width of the mattress and may be placed at portions of the top and portions of the bottom of the mattress.

A foundation for a mattress is formed from a foam block and may also have supports that extend across the foam block's bottom side. The supports can be manufactured with the foam block or may be provided in a kit or separately sourced. The foam block is rigid enough to support a mattress and is compressible so it has a compressed configuration and an expanded configuration and its bottom side may have channels for the supports. In the compressed configuration, the foundation may be folded into a compact form and vacuum-sealed in a plastic membrane which easies in storage, shipping, and delivery of the foundation. When the foundation is delivered to its place of use, the compressed foundation can be removed from its packaging, allowing the foam block to return to its expanded configuration and placed onto a standard bed frame with the supports providing crosswise support across the frame.