Abstract: A cushioning device with an upper foam layer and a lower positioned foam layer, with the upper foam layer having multiple thickness zones defined by different height projections from one zone to another as to provide a thickness variation pattern, one side of the upper foam layer is less contoured when not yet assembled in the cushioning device and a second side is comprised of the multiple thickness zones such that, upon connection of the multiple thickness zones to the lower positioned foam layer, the height differential along a length of the upper foam layer is transmitted as to form a non-planar, crown configuration in the upper surface of the upper foam layer. A method includes roller contouring different height and shaped projection zones including zones with different ratios of peak height to overall zone height.

Abstract: A cushion assembly defining a thickness direction comprises at least one covering layer and a core layer. The core layer comprises a first member and a second member. The covering layer spans continuously across both the first and second members in a direction generally transverse to the thickness direction, and the first member is disposed adjacent a forward area of the cushion assembly. The second member is disposed adjacent a back surface of the first member. The second member has a higher resistance to resilient deformation than the first member, and the first member has a higher resistance to resilient deformation than the at least one covering layer.

Abstract: A cushioning device with an upper foam layer and a lower positioned foam layer, with the upper foam layer having multiple thickness zones defined by different height projections from one zone to another as to provide a thickness variation pattern, one side of the upper foam layer is less contoured when not yet assembled in the cushioning device and a second side is comprised of the multiple thickness zones such that, upon connection of the multiple thickness zones to the lower positioned foam layer, the height differential along a length of the upper foam layer is transmitted as to form a non-planar, crown configuration in the upper surface of the upper foam layer. A method includes roller contouring different height and shaped projection zones including zones with different ratios of peak height to overall zone height.

Abstract: A tool device with projections and valley floors used in profiling material such as foam. The projections having distal recesses surrounded by rims to form flat topped products. A profiler has opposing tooling devices with one or more (e.g., stacked) tool devices and a cutter to form, for example, mirror image flat top output products including single of multi-zoned flat top surface regions with flat surface protuberances. Projections of one tooling device extend within a valley floor region surrounded by a projection of an opposing tooling device or within recesses formed in, for example, an opposing side wall of a projection of the opposing tooling device or projections designed to extend within valley floor regions between adjacent rows of projections on an opposing tooling device, inclusive of conformingly shaped valley floor regions having a common interior configuration to the exterior configuration of an opposing projection to be received.

Abstract: A cushion assembly defining a thickness direction comprises at least one covering layer and a core layer. The core layer comprises a first member and a second member. The covering layer spans continuously across both the first and second members in a direction generally transverse to the thickness direction, and the first member is disposed adjacent a forward area of the cushion assembly. The second member is disposed adjacent a back surface of the first member. The second member has a higher resistance to resilient deformation than the first member, and the first member has a higher resistance to resilient deformation than the at least one covering layer.