WO2017134492A1

WO2017134492A1 - A mattress and a method of manufacturing a mattress

Info

Publication number: WO2017134492A1
Application number: PCT/IB2016/051103
Authority: WO
Inventors: Huseni Bhanpurawala
Original assignee: Huseni Bhanpurawala
Priority date: 2016-02-03
Filing date: 2016-02-29
Publication date: 2017-08-10

Abstract

A mattress and a method for the manufacture of a mattress, relates to the field of bedding systems. A mattress comprised of a shell defining a plurality of horizontal slots along the breadth of said mattress, fixed on a bottom layer. A plurality of resiliently compressible block elements receivable in said plurality of horizontal slots having predetermined varying compressibility values. The variation in the degree of compressibility value ensures the orthopedic support to the user. The shell is then covered by a flexible top layer and enclosed within a mattress ticking.

Description

A MATTRESS AND A METHOD OF MANUFACTURING A MATTRESS

FIELD

The present disclosure relates to the field of bedding systems. DEFINITIONS

Compressibility value of a mattress herein relates to the density of a material used to manufacture the mattress. The denser the material, or the more material used to manufacture it, the more material there is in the mattress to provide support for the weight of a body. Consequently, a high compressibility value indicates low density of the material, and a low compressibility value indicates high density of the material.

Foam Density of a foam material herein refers to the measurement of mass per unit volume of the foam which is expressed in kg/m (Kg. per cubic meter), i.e., 26 Density of Foam represents the Foam weighing 26 Kg per cubic meter of volume.

Resiliently compressible block elements herein refer to the blocks of material used to fill the mattress that provides a sufficient degree of resiliency to absorb compressive forces and return substantially to its original shape or form after the removal of the compressive forces.

Mattress Ticking herein refers to a strong, tightly woven fabric used for making pillows and mattress coverings.

BACKGROUND

A mattress is a large pad required to provide comfortable support to a user resting thereon, thereby ensuring comfortable, deep, and uninterrupted rest to the user.

Traditionally, mattresses are made by stacking horizontal layers of cushioning materials and affixing the layers as such. Such materials provide comfort to the user resting thereon, but do not provide support to the user as a result of which the resting user tends to sink into the mattress, thereby causing harm to the body of the user. Also, the mattresses designed to provide orthopedic support to the resting user are made of layers of materials which do not allow the resting user to sink into the mattress, and are, thus, uncomfortable. Both of the above mentioned mattresses do not meet the modern healthcare requirements of providing both comfort and orthopedic support, as one provides comfort without giving proper support to the resting user thereby inducing pain, and the other provides a good support thereby sparing the user of induced pain, at the cost of comfort to the resting user.

There is, therefore, felt a need for a mattress which provides both comfort and support to the resting user, and which requires fewer inventories and is thus easier to assemble.

OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

It is an object of the present disclosure to provide a mattress that affords comfort to a user resting thereupon.

Another object of the present disclosure is to provide a mattress that affords orthopedic support to the user resting thereupon, so as to reduce pain or any harm to the body-parts of the user.

Yet another object of the present disclosure is to provide a mattress which is customizable, so as to meet specific comfort and health requirements of the user resting thereupon.

Still another object of the present disclosure is to provide a mattress which uses lesser components and is easier to assemble.

Other objects and advantages of the present disclosure will be more apparent from the following description, which are not intended to limit the scope of the present disclosure.

SUMMARY

The present disclosure relates to a mattress and a method of manufacturing the same. In accordance with the present disclosure the mattress comprises a resiliently compressible foam shell defining a plurality of horizontal slots along the breadth of the mattress that is fixed to a bottom layer. A plurality of resiliently compressible block elements receivable in the plurality of horizontal slots having predetermined varying compressibility values. A flexible top layer is provided for sealing the shell alongwith the resiliently compressible block elements. The variation in compressibility values ensures the orthopedic support to the user. In accordance with the present disclosure, the method of manufacturing the mattress comprises fabricating the resiliently compressible foam shell defining the plurality of horizontal slots along breadth of the mattress, integrally providing or securing the bottom layer, fabricating the plurality of resiliently compressible block elements having shapes complementary to the plurality of horizontal slots , receiving the resiliently compressible block elements in the plurality of horizontal slots in a predetermined varying arrangement, and securing a flexible top layer.

The plurality of horizontal slots is configured in the form of rows along the breadth of the mattress such that the number of rows is in multiples of seven.

The flexible top layer is configured with a layer of a gel pad on its upper surface.

The material for the shell and the block elements for filling up of the horizontal slots are selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam, cotton and combinations thereof.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

A mattress of the present disclosure will now be described with the help of the accompanying drawing, in which:

Figure 1 illustrates an exploded view of the different layers of a mattress, in accordance with an embodiment of the present disclosure; and

Figure 2 illustrates an exploded view of the layers of a mattress, in accordance with another embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure provides a mattress and a method of manufacturing the same.

A mattress is a large pad for supporting a resting user. The mattress provides both support and comfort to the resting user. Neither the traditional mattresses, that provide only comfort, nor the mattresses designed to provide only orthopedic support to the resting user, meet the modern healthcare requirements of providing both comfort and support to the user. The perfect balance of comfort and support is specific to each individual user resting upon the mattress and is based on the individual characteristics such as age, body mass index (BMI), and lifestyle. The traditional designs and manufacturing techniques do not support adjusting the compressibility of the mattresses to suit individual needs.

The compressibility profile of the mattress depends upon the compressibility value of the materials used in the manufacture of the mattress which in-turn depends upon the density of the materials.

In case of foam materials, the foam material density is a measurement of mass per unit volume. More the mass of the material used to manufacture the mattress, more is the support provided by the mattress to the weight of the user resting thereupon, thereby implying an inverse proportionality between the density and the compressibility of the foam material. Consequently, low density of foam material indicates a high compressibility value and high density of foam material indicates a low compressibility value.

The present disclosure provides a mattress and a method of manufacturing the mattress. The mattress of the present disclosure provides the option of predetermining compressibility profiles for balancing the comfort and support to meet specific comfort and health requirements of individual user(s) resting on the mattress.

The mattress, of the present disclosure, will now be described with reference to figure 1 and figure 2.

Figure 1 illustrates an exploded view of a mattress 100 in accordance with an embodiment of the present disclosure. The mattress 100 comprises a resiliently compressible foam shell 104 (hereinafter referred to as "the shell 104") defining a plurality of horizontal slots along the breadth of the mattress 100 that is fixed on or integral with a bottom layer 102. A plurality of resiliently compressible block elements 106 (hereinafter referred to as "the block elements 106") is received in a plurality of horizontal slots in the shell 104 having predetermined compressibility values. A flexible top layer 108 is provided for sealing the shell 104.

In accordance with the present disclosure, the shell 104 is fabricated, defining the plurality of horizontal slots configured in the form of rows along the breadth of the mattress such that the number of rows is in multiples of seven. The bottom layer 102 is either integrated with the shell 100 or is secured therewith. The plurality of block elements 106 are fabricated having shapes complementary to the plurality of horizontal slots and are received in the plurality of horizontal slots of the shell 104 in a predetermined varying arrangement such that a compressibility profile is realized to provide orthopedic comfort. The shell 104 is secured with the flexible top layer 108.

The process of fabricating inter alia involves the process of molding.

The material of the shell 104 is selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam, and combinations thereof.

The material of the plurality of block elements 106 is selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam, polyester wadding, cotton, springs made of steel wire or plastic, polyester fiber, wool, Down & Feather, and combinations thereof.

The material of the flexible top layer 108 is selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, polyester wadding, cotton, polyester fiber, wool, and combinations thereof. The flexible top layer 108 is provided with a layer of a gel pad on its upper surface.

The bottom layer is of a material selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam and combinations thereof.

In an embodiment, the bottom layer 102 is integral with the shell 104 wherein the plurality of horizontal slots are recessed in the shell 104. In another embodiment, the shell 104 is configured with a plurality of slits through the shell 104 which is fixed to the bottom layer 102 wherein the plurality of horizontal slots are defined by the walls of the plurality of slits and the bottom layer 102.

In an embodiment, an adhesive layer is provided between the plurality of block elements 106 and the inner surface of the plurality of horizontal slots in the shell 104.

In one embodiment, the mattress 100 is configured such that the walls of the shell 104 have perforations or through-holes, enabling venting of air through the shell 104, thereby allowing the shell 104 to be a breathable shell. In yet another embodiment, the cross-section of the plurality of horizontal slots in the shell 104 is selected from the group consisting of polygonal, quadrilateral, square, and combinations thereof. The cross-section of the plurality of block elements 106 is complementary to the cross-section of the horizontal slots in the shell 104.

In still another embodiment, the mattress 100 is enclosed within a mattress ticking which may be stitched to encase the bottom layer 102, the plurality of block elements 106 received in the shell 104 and the flexible top layer 108. In yet another embodiment, the mattress 100 may be zipped to allow for the opening and closing of the mattress 100 for reconfiguration.

In one embodiment, the plurality of horizontal slots is arranged in the form of rows wherein the rows define the breadth of the mattress 100, and the plurality of block elements 106 are selected to be received in the horizontal slots such that the compressibility value of the plurality of block elements 106 received in the rows increases from the center of the shell 104 towards the ends of the shell 104. In another embodiment, the increase in compressibility value of the block elements 106 from the center of the shell 104 towards the ends of the shell 104 is sequential. In yet another embodiment, two halves of each of the block elements 106 are received in each of the plurality of horizontal slots such that compressibility value of one- half of each of the block elements 106 received in each of the plurality of horizontal slots on one half portion of the shell 104A varies from compressibility value of one -half of each of the block elements 106 received in each of the plurality of horizontal slots on the other half portion of the shell 104B to support multiple users.

In an exemplary embodiment, the mattress 100, for a queen sized bed, is optimized for providing orthopedic support and comfort to a user resting thereon, the mattress 100 having the following configuration: i. the bottom layer 102 having a thickness of at least 2 inches; ii. the resiliently compressible foam shell 104, having a rectangular shape with a thickness of at least 4 inches, a length of 2 meters and a breadth of 1.6 meters, fixed on the bottom layer 102 forming the plurality of horizontal slots along the breadth of the mattress 100 thereon; iii. each of the plurality of horizontal slots having a rectangular cross-section with a length of 8 inches / 20.3 centimeters and a breadth of 184.76 centimeters, configured in the form of seven rows, wherein the plurality of rectangular shaped horizontal slots in the shell 104 are spaced apart from each other by the walls of the shell 104 having a thickness of 3 inches; iv. the plurality of resiliently compressible block elements 106 made of foam material, having a shape complementary to that of the plurality of rectangular shaped horizontal slots, receivable in the plurality of horizontal slots of the shell 104; v. compressibility value of each of the foam block elements 106 received in the rows of the plurality of horizontal slots is sequentially increased from the center of the shell 104 towards the ends of the shell 104, or the density rating of the foam block elements 106 received in the plurality of horizontal slots is sequentially decreased from the center of the shell 104 towards the ends of the shell 104, such that:

~ foam block elements 106G and 106 A having a density rating of 26 are received by the rows, first from both the ends of the shell 104,

~ foam block elements 106F and 106B having a density rating of 30 are received by the rows, second from both the ends of the shell 104,

~ foam block elements 106E and 106C having a density rating of 40 are received by rows, third from both the ends of the shell 104, and

~ foam block element 106D having a density rating of 50 is received by the center row or the row, fourth from either end of the shell 104, thereby achieving a compressibility profile that provides orthopedic support to the user and maintains horizontal alignment of the user resting on the mattress 100; and vi. the flexible top layer 108 having thickness of 2 inches.

In another exemplary embodiment, the mattress 100 for a king sized bed is optimized for providing orthopedic support and comfort to two users resting thereon, the mattress having the same configuration as the one disclosed in the aforementioned embodiment (which is not repeated herein for the sake of brevity) with the following variations / modifications: i. the shell 104, having a lenngth of 2 meters and a breadth of 1.8 meters; ii. the plurality of rectangular shaped horizontal slots, are configured in the form of seven rows; iii. two halves of the block elements 106 are received in each of the plurality of horizontal slots, iv. compressibility value of one-half of each of the block elements 106 received in each of the plurality of horizontal slots on one half portion of the shell 104A, varies from compressibility value of one -half of each of the block elements 106 received in each of the plurality of horizontal slots on the other half portion of the shell 104B. Table 1 illustrates the the density of foam block elements 106 filled in the two half portions of the shell 104 to achieve an exemplary predetermined compressibility profiles for the male and the female.

Table 1.

The compressibility profile shown in Table 1 orthopedically supports a female user on one portion of the shell 104 A and a male user on the other half portion of the shell 104B respectively, corresponding to their different body weights, and maintaining a horizontal alignment of both users resting thereon the mattress 100. In alternate variations of the above exemplary embodiment, the shape, size and material of the resiliently compressible foam shell 104 and the plurality of resiliently compressible foam block elements 106 are chosen so as to achieve the predetermined compressibility profile of the mattress 100.

In alternate embodiments, the plurality of block elements 106 is configured such that either the upper surface of the block elements 106 is flush with the upper surface of the shell 104, or predetermined rows of block elements selected from the plurality of block elements 106 are raised above the surface of the shell 104 to define a pillow formation on the mattress 100.

In another embodiment, the shape, size, and material of the shell 104, and the shape, size, and compressibility value of the plurality of block elements 106 may be chosen such as to achieve predetermined compressibility profiles of the mattress 100 to meet specific comfort and health requirements of individual(s). Examples of the mattress 100 having pre-determined compressibility profiles to meet specific comfort and health requirements of individual(s) are as follows: i. The mattress 100 for individual(s) with back pain wherein predetermined rows of block elements selected from the plurality of block elements 106 are raised above the surface of the shell 104 to define a slightly raised platform under the small of back and pillow formation under the knees for the individual(s) to maintain an orthopedically supporting profile to the spine while resting. ii. The mattress 100 for individual(s) with gastro-esophageal reflux disease wherein predetermined rows of block elements selected from the plurality of block elements 106 are raised above the surface of the shell 104 to define a pillow formation on the top of the mattress 100 for raising the resting head of the individual(s). Additionally, for individual(s) with a chronic/advanced state of the ailment, compressibility value of the plurality of block elements 106 received in the rows decreases from bottom of the shell 104 towards the top of the shell 104 sequentially to achieve a raised from the top (inclined) profile of the mattress 100 suited to the orthopedic requirement of the individual(s). iii. The mattress 100 for individual(s) with nocturnal neuropathic pain in diabetic patients or complaints of peripheral neuropathy wherein predetermined rows of block elements selected from the plurality of block elements 106 such that the upper and lower portions of the mattress are raised, or other variations with different levels of density of the block elements 106, with different types of flexible top layer(s) 108.

In another embodiment, the mattress 100 is configured to support two users sharing the mattress 100, wherein two halves of the plurality of block elements (106) are received in each of the plurality of horizontal slots such that the shape, size, and compressibility value of one- half of each of the plurality of block elements 106 received in each of the plurality of horizontal slots on one half portion of the shell 104A varies from compressibility value of one -half of each of the block elements 106 received in each of the plurality of horizontal slots on the other half portion of the shell 104B, to meet the different orthopedic and comfort requirements of both the users.

Figure 2 illustrates an exploded view of a mattress 200 in accordance with another embodiment of the present disclosure. The mattress 200 comprises a resiliently compressible foam shell 204 defining a plurality of horizontal slots that is integral with a bottom layer 202. A plurality of resiliently compressible block elements 206 is received in the plurality of horizontal slots in the shell 204 having predetermined compressibility values such that the plurality of block elements 206 are raised above the surface of the shell 204 to define a pillow formation on the mattress 200.

The mattress and the method of manufacturing the mattress 100 described herein above, ensures a lighter mattress which maintains a horizontal alignment of the resting user by ensuring that the weight of the torso is supported by rows of high density material (having a low compressibility value) than the limbs of the user, which are supported by row of low density material (having a high compressibility value) owing to the relative difference between the weights of the torso and the limbs of the user.

The mattress also requires limited number of components is thus easier to assemble. TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of:

• a mattress that provides comfort to the user resting thereon;

• a mattress that provides orthopedic support to the user resting thereon; • a mattress which is customizable so as to meet the specific comfort and health requirements of the user resting thereon;

• a mattress that maintains a horizontal alignment of the resting user, thereby eliminating the chances of pain or any harm to the user resting thereon;

• a mattress that provides the user with the choice of filling materials suited to his needs and requirements;

• a mattress that provides the option of unique configurations for various medical requirements of supporting particular body parts of the user resting thereon; and

• a mattress which uses fewer inventories and is easy to assemble.

The disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

The embodiments hereinabove and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully revealed the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A mattress (100) comprising, i. a resiliently compressible foam shell (104) defining a plurality of horizontal slots along the breadth of said mattress (100); ii. a bottom layer (102); iii. a plurality of resiliently compressible block elements (106) receivable in said plurality of horizontal slots having predetermined varying compressibility values; and iv. a flexible top layer (108).

2. The mattress (100) as claimed in claim 1, wherein said shell (104), said bottom layer (102) and said flexible top layer (108) are of a material selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam and combinations thereof.

3. The mattress (100) as claimed in claim 1, wherein said plurality of block elements (106) are of a material selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam, polyester wadding, cotton, springs made of steel wire or plastic, polyester fiber, wool, Down & Feather and combinations thereof.

4. The mattress (100) as claimed in claim 1, wherein said bottom layer (102) is integral with said shell (104) and said plurality of horizontal slots are recessed in said shell (104).

5. The mattress as claimed in claim 1, wherein said shell (104) is configured with a plurality of slits through said shell (104); and said bottom layer (102) is fixed to said shell (104) and said plurality of horizontal slots are defined by the walls of said slits and said bottom layer (102).

6. The mattress (100) as claimed in claim 1, wherein said plurality of horizontal slots are configured in rows along the breadth of said mattress (100) such that the number of said rows is in multiple of seven.

7. The mattress (100) as claimed in claim 1, wherein the upper surface of said flexible top layer (108) is configured with a layer of gel pad.

8. The mattress as claimed in claim 1, wherein an adhesive layer is provided between said plurality of block elements (106) and the inner surface of said plurality of horizontal slots in said shell (104); either on said block elements or on the inner surface of said plurality of horizontal slots in said shell (104), or on both.

9. The mattress (100) as claimed in claim 1, wherein the walls of said shell (104) have perforations, enabling venting of air through said shell (104).

10. The mattress (100) as claimed in claim 1, wherein the cross-section of said horizontal slots in said shell (104) is selected from the group consisting of polygonal, quadrilateral, square, and combinations thereof; and the cross-section of said plurality of block elements (106) is complementary to the cross-section of said horizontal slots in said shell (104).

11. The mattress as claimed in claim 1, wherein said mattress (100) is enclosed within a mattress ticking.

12. The mattress as claimed in claim 1, wherein said plurality of block elements (106) are configured such that the upper surface of said plurality of block elements (106) is flush with the upper surface of said shell (104).

13. The mattress as claimed in claim 1, wherein said plurality of block elements (106) are configured such that predetermined rows of block elements selected from said plurality of block elements (106) are raised above the upper surface of said shell (104) to define a pillow formation on said mattress (100).

14. The mattress (100) as claimed in claim 1, wherein said shell (104) is rectangular having a length ranging between 1.8 meters and 2 meters, breadth ranging between 1 meter to 1.8 meters, and the thickness of said shell (104) ranging between 4 inches / 10 centimeters and 10 inches / 25 centimeters.

15. The mattress as claimed in any of claim 1 or claim 6, wherein said plurality of horizontal slots are arranged in the form of rows along the breadth of said mattress (100), and said plurality of block elements (106) are selected to be received in said plurality of horizontal slots such that compressibility value of said plurality of block elements (106) received in said rows increases from the center of said shell (104) towards either end of said shell (104).

16. The mattress as claimed in claim 15, wherein said increase in compressibility value of said plurality of block elements (106) from said center of said shell (104) towards said ends of said shell (104) is sequential.

17. The mattress as claimed in claim 1 or claim 15, wherein two halves of said plurality of block elements (106) are received in each of said plurality of horizontal slots, such that compressibility value of one-half of each of said plurality of block elements (106) received in each of said plurality of horizontal slots on one half portion of said shell (104 A) varies from compressibility value of one -half of each of said plurality of block elements (106) received in each of said plurality of horizontal slots on the other half portion of said shell (104B).

18. A mattress (100) comprising, i. a bottom layer (102) having a thickness of 2 inches; ii. a rectangular resiliently compressible foam shell (104), having a thickness of 4 inches / 10.16 centimeters, a length of 2 meters and a breadth of 1.8 meters; said shell (104) comprising: a plurality of horizontal slots, having a rectangular cross section with a length of 8 inches / 20.3 centimeters and breadth of 184.76 centimeters, configured on said shell (104) in the form of seven rows, wherein said plurality of horizontal slots are spaced from each other by walls of said shell (104) having a thickness of 3 inches / 7.62 centimeters; iii. a plurality of resiliently compressible block elements (106) of foam material, receivable in said plurality of horizontal slots and having a shape and size complementary to that of said plurality of rectangular shaped horizontal slots; wherein compressibility value of each of said foam block elements (106) received in said rows of said plurality of horizontal slots is sequentially increased from the center of said shell (104) towards either ends of said shell (104) or density rating of said foam block elements (106) received in said plurality of horizontal slots is sequentially decreased from the center of said shell (104) towards said ends of said shell (104); and iv. a flexible top layer (108) having thickness of 2 inches / 5.08 centimeters.

19. The mattress (100) as claimed in claim 18, wherein each of said foam block elements (106):

• received by rows in the end at both ends of said shell (104) have a density rating of 26 (rows of foam block elements 106G and 106A);

• received by rows but one-from the end at both ends of said shell (104) have a density rating of 30 (rows of foam block elements 106F and 106B);

• received by rows but two from the end at both ends of said shell (104) have a density rating of 40 (rows of foam block elements 106E and 106C); and

• received by the center row or the row, but third from either end of said shell (104) has a density rating of 50 (row of foam block elements 106D), thereby achieving a compressibility profile such as to orthopedically support a user.

20. A method of manufacturing a mattress (100), said method comprising the following steps: i. fabricating a resiliently compressible foam shell (104) defining a plurality of horizontal slots configured along the breadth of said mattress (100); ii. integrally providing or securing a bottom layer (102); iii. fabricating a plurality of resiliently compressible block elements (106) having shapes complementary to said plurality of horizontal slots, received in said plurality of horizontal slots in a predetermined varying arrangement; and iv. securing a flexible top layer (108).

21. The method as claimed in claim 20, an adhesive is applied between said plurality of block elements (106) and the inner surface of said plurality of horizontal slots in said shell (104); either on said block elements or on said inner surface of said plurality of horizontal slots in said shell (104), or on both.

22. The method as claimed in claim 20, wherein said method comprises filling rows of said plurality of horizontal slots in said shell (104) with said plurality of block elements (106) such that compressibility values of said plurality of block elements (106) received in said rows increase from the center of said shell (104) towards either end of said shell (104).

23. The method as claimed in claim 20, wherein said method comprises filling said plurality of horizontal slots in said shell (104) with two halves of said plurality of block elements (106) such that compressibility value of one-half of each of said plurality of block elements (106) received in one half of each of said plurality of horizontal slots on one half portion of said shell (104 A) varies from compressibility value of one-half of each of said plurality of block elements (106) received in one half of each of said plurality of horizontal slots on other half portion of said shell (104B).

24. A method of manufacturing a mattress (100) customized to requirement of at least one user depending on the need for orthopedic support of said at least one user, said method comprising the following steps:

- fabricating a resiliently compressible foam shell (104) defining a plurality of horizontal slots configured in rows along the breadth of said mattress (100);

- integrally providing or securing a bottom layer (102);

- determining an orthopedic need of said at least one user;

- selecting a plurality of resiliently compressible block elements (106) with shapes complementary to said plurality of horizontal slots having predetermined compressibility values suited to said orthopedic needs of said at least one user, received in said plurality of horizontal slots in a predetermined varying arrangement; and

- securing a flexible top layer (108).

25. The method as claimed in claim 24, wherein said method comprises determining specific comfort and health requirements of said at least one user; thereafter selecting shape, size and material of said shell (104), and shape, size and compressibility value of said plurality of block elements (106) such as to achieve a corresponding predetermined compressibility profile of said mattress (100).