Foam mattress with progressive support characteristics and method for manufacturing the same

A method for manufacturing a mattress, the method comprising:

• cutting a first foam member in half to form first and second top layers, a bottom surface of the first top layer comprising a series of protrusions and recessions and a top surface of the second top layer comprising a series of protrusions and recessions opposite to the series of protrusions and recessions of the first top layer;
• cutting a second foam member in half to form first and second bottom layers, a bottom surface of the first bottom layer comprising a series of protrusions and recessions and a top surface of the second bottom layer comprising a series of protrusions and recessions opposite to the series of protrusions and recessions of the first bottom layer;
• and
• positioning the first top layer on top of the second bottom layer such that the protrusions of the top surface of the second bottom layer protrude into the recessions of the bottom surface of the first top layer and the protrusions of the bottom surface of the first top layer protrude into the recessions of the top surface of the second bottom layer;
• wherein the cutting the first foam member in half and the cutting the second foam member in half are performed such that, when the first top layer is positioned on top of the second bottom layer, most protruded surfaces of the protrusions of the bottom surface of the first top layer are separated from corresponding surfaces of the recessions of the top surface of the second bottom layer by a channel, and there is no channel between most protruded surfaces of the protrusions of the top surface of the second bottom layer and corresponding surfaces of the recessions of the bottom surface of the first top layer.