Patent ID: 7376996

Claim:
A multi-section mattress overlay, comprising: a first generally rectangular section made from a first honeycomb core formed of undulated strips of resilient thermoplastic material, thermal compression bonded together and expanded to form cell walls defining a first plurality of contiguous regularly shaped cells extending between a first core face of the first core and a second core face of the first core, a first facing sheet bonded to at least one of said first and second core faces; a second generally rectangular section made from a second honeycomb core formed of undulated strips of resilient thermoplastic material, thermal compression bonded together and expanded to form cell walls defining a second plurality of contiguous regularly shaped cells extending between a third core face of the second core and a fourth core face of the second core, a second facing sheet bonded to at least one of said third and fourth core faces, said second section being positioned with one side thereof immediately adjacent an opposing side of said first section; and means forming a seam joining said first and second sections together along the entire lengths of said one side and said opposing side, said seam being formed by bonding a planar portion of said first face extending along said one side to a portion of said third face extending along said opposing side in a stacked relationship, and by orienting the bonded portions of said first and third faces such that they extend away from a plane including said first and third faces and toward a plane including said second and fourth faces.