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 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.

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.

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.

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.

This invention provides a mat, comprising: an upper surface; a lower surface; a porous structure located between said upper surface and said lower surface, said porous structure including silica gel. The mat according to this invention can be used as, for example, a pillow, seat cushion, back cushion or mattress, or part of a chair seat or chair back.

This invention provides a mat, comprising: an upper surface; a lower surface; a porous structure located between said upper surface and said lower surface, said porous structure including silica gel. The mat according to this invention can be used as, for example, a pillow, seat cushion, back cushion or mattress, or part of a chair seat or chair back.

A foundation for a mattress is formed from one or more single-layer, unitary foam blocks with supports that extend across each foam block's bottom side. The supports provide crosswise support across a bed frame and can be directly attached to 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 and vacuum-sealed in a plastic membrane which provides benefits for storing, shipping, and delivering the foundation. When the foundation is delivered to its place of use, the compressed foundation is removed from its packaging, allowing the foam block to return to its expanded configuration.

A foundation for a mattress is formed from one or more single-layer, unitary foam blocks with supports that extend across each foam block's bottom side. The supports provide crosswise support across a bed frame and can be directly attached to 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 and vacuum-sealed in a plastic membrane which provides benefits for storing, shipping, and delivering the foundation. When the foundation is delivered to its place of use, the compressed foundation is removed from its packaging, allowing the foam block to return to its expanded configuration.