Abstract: A method of making a headrest includes folding a first sheet of foam into a foam sleeve. The foam sleeve is slid over an internal core part of the headrest. The foam sleeve and the core part in turn are covered with an outermost cover. The cover is formed from (i) a first layer of material corresponding to a front face of the cover, (ii) a second sheet of foam having a periphery substantially the same shape as the first layer of material, affixed to a backside of the first layer, (iii) a second layer of the material corresponding to a rear face of the cover, and (iv) a third sheet of foam having a periphery substantially the same shape as the second layer of material, affixed to a backside of the second layer. The front and rear faces are joined together to form the cover.

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 and contain one or more gels.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.

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 and contain one or more gels.

Abstract: A gutter insert formed of a flexible open cell porous foam has five or more sides and forms an inverted “V” or check-mark shape. Four gutter inserts may be cut from one column of foam material, thereby reducing foam waste. The four gutter inserts may be shipped nested together in columnar form, and separated at the jobsite just before installation.