Customizable mattress with multiple sleep zones to improve spinal alignment during sleep

Abstract

This invention includes a method to produce a customizable and user-configurable mattress foam core which comprises a plurality of transversely extended foam rods that were cut during the mattress production process. These transversely extended foam rods typically have a cross section of a convex shape, including triangles, squares, rectangles, circles, ovals and hexagons. These transversely extended foam rods can be replaced with foam rods of different firmness, creating more than 10 zones with varying firmness in each zone thus tailoring to the sleeper's needs, adjusting for their differences in height, weight, sleeping position, and comfort preference. Also, these zones together allow the user to configure the mattress for spinal alignment.The transversely extended replacement foam rods typically have cross sections that are substantially the same shape as the pre-cut foam rods, but may also be of different shape. In one embodiment, the transversely extended replacement foam rods comprises foams of two or more different firmness in the transverse direction, thus allowing the mattress to be customized for multiple users with different sleeping needs.

1 . A method for making a customizable, configurable, multi-zone mattress comprising
 mattress core is cut comprising a plurality of transversely extended pre-cut foam rods to be replaced with transversely extended replacement foam rods, creating zones of varying firmness in the longitudinal direction of the mattress,
 wherein the pre-cut foam rods and the replacement foam rods are configured to have cross sections of arbitrary shapes; and 
   an horizontal slit is cut extending longitudinally at approximately the mid height of the pre- cut foam rods to provide the user access to the pre-cut foam rods.   
     
     
         2 . The method according to  claim 1 , comprising configuring one or more of longitudinally extended pre-cut foam rods which divide the mattress into two or more sectors. 
     
     
         3 . (canceled) 
     
     
         4 . The method of  claim 1 , comprising configuring the pre-cut foam rods and the replacement foam rods to have cross sections of polygons including triangles, squares, trapezoids, and circles. 
     
     
         5 . The method of  claim 1 , comprising configuring the pre-cut foam rods to have different cross sections at different locations in the mattress. 
     
     
         6 . The method of  claim 1 , comprising configuring the replacement foam rods to have different cross sections than the pre-cut foam rods. 
     
     
         7 . The method of  claim 1 , comprising configuring a plurality of replacement foam rods to have bigger sizes than the pre-cut foam rods, to create a taller height in the lumbar and in the knee regions. 
     
     
         8 . (canceled) 
     
     
         9 . The method of  claim 1 , comprising configuring the pre-cut foam rods to be in the top layer or in the bottom layer of the mattress. 
     
     
         10 . The method of  claim 1 , comprising configuring the pre-cut foam rods and the replacement foam rods to be in multiple layers of the mattress. 
     
     
         11 . The method of  claim 1 , comprising configuring the mattress layers and the replacement foam rods to be made from any combination of polyurethane, natural latex, polyethylene, polystyrene, woven fabric and foam gel. 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . The method of  claim 1 , the transversely extended replacement foam rods comprises foams of two or more different firmness in the transverse direction. 
     
     
         15 . (canceled) 
     
     
         16 . The method of  claim 1 , comprising configuring the replacement foam rods to be capable of being pre-heated or pre-cooled outside of the mattress. 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled)