Abstract: Apparatus and methods for cutting compressible cellular polymers such as polyurethane foam, are characterized by a first die roller and a pressure roller, wherein both rollers define raised portions separated by recesses or depressions, and the raised portions on the first die roller register with the recesses of the pressure roller at a nip formed between the rollers. Portions of the polymer material extruded into the spaces between the raised portions of the first die roller are cut away, such that the cut product conforms substantially to the surface geometry of the first die roller, and the depth of cut is greater than with prior rotary cutting methods.

Abstract: A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft3/ft2/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress.

Abstract: A mattress constructed with multiple foam layers joined together provides reclining support with pressure redistribution for heavy weight persons, particularly those weighing over 350 pounds. The mattress includes: a core layer having a substantially planar top surface and at least two spaced apart regions in a bottom surface from which foam material has been extracted to leave cavities separated by an interconnected network of foam walls, a top layer of viscoelastic foam with an air permeability above 60 ft3/ft2/min, and a bottom layer of stiffer supporting foam. The open cavities of the core layer are directed away from the body supporting top surface of the mattress.