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.

A nonwoven fabric used for a foamed article reinforcing material to be bonded to a foamed material to reinforce the foamed article is a single-layer material in which stacked layers of a web are bonded together, has a thickness of 1 to 8 mm under a load of 7 g/cm.sup.2, and has a delamination strength of 0.05 to 2.45 N/cm. The delamination strength is a value of the pulling force required to peel the bonded layers of the web apart.

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.

A foam mattress with an adjustable firmness by inserting or removing filling bodies into openings on at least one side thereof is disclosed. The adjustment of the firmness may be performed by an owner/user of the mattress. The ridged patterns may form openings that enable the insertion and or removal of filling bodies that provide further adjustments to the firmness (or softness) of the mattress in addition to the other factors discussed above. The mattress may also be partitioned to allow the firmness on a first portion of the mattress to be adjusted independently of the firmness of a second portion of the mattress, and vice versa.

A foam mattress with an adjustable firmness by inserting or removing filling bodies into openings on at least one side thereof is disclosed. The adjustment of the firmness may be performed by an owner/user of the mattress. The ridged patterns may form openings that enable the insertion and or removal of filling bodies that provide further adjustments to the firmness (or softness) of the mattress in addition to the other factors discussed above. The mattress may also be partitioned to allow the firmness on a first portion of the mattress to be adjusted independently of the firmness of a second portion of the mattress, and vice versa.

A foam mattress is disclosed. The foam mattress includes a first foam layer and a second foam layer. A top surface of the second foam layer is in contact with a bottom surface of the first foam layer. The top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges. The first ridged pattern has a first dimension between two ridges of the first plurality of ridges and a second dimension at a bottom of between ridges of the first plurality of ridges, wherein a firmness of the mattress is dependent on a ratio of the first dimension and the second dimension.

A foam mattress is disclosed. The foam mattress includes a first foam layer and a second foam layer. A top surface of the second foam layer is in contact with a bottom surface of the first foam layer. The top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges. The first ridged pattern has a first dimension between two ridges of the first plurality of ridges and a second dimension at a bottom of between ridges of the first plurality of ridges, wherein a firmness of the mattress is dependent on a ratio of the first dimension and the second dimension.