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.

A cushion may include a cushioning element. The cushioning element may comprise an elastomeric material and one or more reinforcing features positioned at one or more exterior portions of the cushioning element.

A cushion may include a cushioning element. The cushioning element may comprise an elastomeric material and one or more reinforcing features positioned at one or more exterior portions of the cushioning element.

A pocketed buckling member assembly comprises a plurality of parallel strings of pocketed buckling members. Each string is joined to at least one adjacent string. Each string comprising one piece of fabric folded around the buckling members into first and second opposed plies. Pockets are formed along each string by transverse seams joining the first and second plies. At least one buckling member is positioned in each pocket. At least some of the buckling members may have foam therein.

A pocketed buckling member assembly comprises a plurality of parallel strings of pocketed buckling members. Each string is joined to at least one adjacent string. Each string comprising one piece of fabric folded around the buckling members into first and second opposed plies. Pockets are formed along each string by transverse seams joining the first and second plies. At least one buckling member is positioned in each pocket. At least some of the buckling members may have foam therein.

Cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric being joined together to form discrete spring-containing pockets; wherein the cover material is fastened to the microcoil sheet by one or more seams. Also provided is a cushioned or upholstered article (such as a mattress, mattress topper, seat, chair or loose cushion) comprising cushioning material according to any preceding claim. Also provided is a method of manufacturing cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric having been joined together to form discrete spring-containing pockets; the method comprising fastening the cover material to the microcoil sheet by one or more seams.

Cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric being joined together to form discrete spring-containing pockets; wherein the cover material is fastened to the microcoil sheet by one or more seams. Also provided is a cushioned or upholstered article (such as a mattress, mattress topper, seat, chair or loose cushion) comprising cushioning material according to any preceding claim. Also provided is a method of manufacturing cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric having been joined together to form discrete spring-containing pockets; the method comprising fastening the cover material to the microcoil sheet by one or more seams.

An adjustable mattress assembly including a support tray, an inflatable air chamber, a support block, and upper pad is provided. The inflatable air chamber is removably disposed in the support tray. The support block is removably and reorientably disposed in the support tray. The support block includes a first layer formed of a first foam and a second layer bonded to the first layer. The second layer is formed of a second foam. The first foam is firmer than the second foam. The upper pad removably overlays the support tray, the inflatable air chamber, and the support block.

An adjustable mattress assembly including a support tray, an inflatable air chamber, a support block, and upper pad is provided. The inflatable air chamber is removably disposed in the support tray. The support block is removably and reorientably disposed in the support tray. The support block includes a first layer formed of a first foam and a second layer bonded to the first layer. The second layer is formed of a second foam. The first foam is firmer than the second foam. The upper pad removably overlays the support tray, the inflatable air chamber, and the support block.

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.