Patent ID: 7293311

Claim:
A method of making a mattress component, the method comprising: providing a first layer of a first material to be assembled in a mattress over which a user will lie, the first layer having a surface; shaping first mating patterns in the surface of the first layer in areas corresponding to a position where hips of the user will rest on the mattress, the mating patterns in the surface of the first layer including peaks and valleys and resulting in a greater effective thickness of the first layer in areas corresponding to the position where the hips of the user will rest, and a lesser effective thickness of the first layer in other areas; shaping second mating patterns in the surface of the first layer in areas corresponding to a position where shoulders of the user will rest on the mattress, the second mating patterns in the surface of the first layer including peaks and valleys and resulting in a greater effective thickness of the first layer in areas corresponding to the position where the shoulders of the user will rest, and a lesser effective thickness of the first layer in other areas; providing a second layer of a second material having different properties than the first material, the second layer having a surface; shaping mating patterns in the surface of the second layer in areas corresponding to the first and second mating patterns in the surface of the first layer when the first and second layers are aligned, the mating patterns of the second layer being shaped to substantially match the mating patterns of the first layer; and assembling the first and second layers together, the mating patterns in the surface of the first layer substantially fitting with the mating patterns in the surface of the second layer in the areas corresponding to the position where hips and shoulders of the user will rest on the mattress.