A mattress or mattress topper includes a cushioning element having an elastomeric material forming intersecting buckling walls that define hollow columns, and a knitted fabric disposed over the cushioning element and configured to move independently of the buckling walls. The elastomeric material includes an elastomeric polymer and a plasticizer. The knitted fabric includes a first layer of stretchable material; a second layer of stretchable material; and a layer of stretchable fill material between the first layer of stretchable material and the second layer of stretchable material. The first layer of stretchable material is knitted together with the second layer of stretchable material as a unitary sheet of fabric including the layer of stretchable fill material. A method of forming a mattress or mattress topper includes disposing a knitted fabric over a cushioning element comprising intersecting buckling walls and configuring the knitted fabric to move independently of the buckling walls.

A method of manufacturing a multi-hardness and multi-elasticity foam mattress in which a plurality of foam blocks are formed integrally with each other by use of a continuous foaming process the method comprising the steps of: arranging a plurality of nozzles above one end of a molding plate; installing a separation wall between two adjacent ones of the respective nozzles arranged at the molding plate; laminating a release paper on the top of the molding plate; spraying foaming solutions from the nozzles, respectively, wherein the release paper moves in a direction toward the other end of the molding plate corresponding to a moving speed of the foaming solution; and molding a foam body having a plurality of zones where a plurality of unit foam blocks have multi-hardnesses and multi-elasticities.

A method of manufacturing a multi-hardness and multi-elasticity foam mattress in which a plurality of foam blocks are formed integrally with each other by use of a continuous foaming process the method comprising the steps of: arranging a plurality of nozzles above one end of a molding plate; installing a separation wall between two adjacent ones of the respective nozzles arranged at the molding plate; laminating a release paper on the top of the molding plate; spraying foaming solutions from the nozzles, respectively, wherein the release paper moves in a direction toward the other end of the molding plate corresponding to a moving speed of the foaming solution; and molding a foam body having a plurality of zones where a plurality of unit foam blocks have multi-hardnesses and multi-elasticities.

In described examples, a cushioning unit assembler includes first, second, third, and fourth rows of welding heads, a transport, and a feed module. The welding heads have a welding position and a retracted position. A main axis of the welding heads is oriented in a first dimension while in the welding position. The transport is disposed above the rows of welding heads. The transport has a main axis oriented in a second dimension perpendicular to the first dimension. The feed module includes a pocketed spring intake and a pocketed spring outflow. The transport is mechanically coupled to enable the feed module to move in the second dimension along a scope of movement. An exit aperture of the outflow vertically aligns with welding heads of the first row that are in the welding position, and vertically aligns with welding heads of the second row that are in the welding position.

In described examples, a cushioning unit assembler includes first, second, third, and fourth rows of welding heads, a transport, and a feed module. The welding heads have a welding position and a retracted position. A main axis of the welding heads is oriented in a first dimension while in the welding position. The transport is disposed above the rows of welding heads. The transport has a main axis oriented in a second dimension perpendicular to the first dimension. The feed module includes a pocketed spring intake and a pocketed spring outflow. The transport is mechanically coupled to enable the feed module to move in the second dimension along a scope of movement. An exit aperture of the outflow vertically aligns with welding heads of the first row that are in the welding position, and vertically aligns with welding heads of the second row that are in the welding position.

A method for manufacturing a seat cushion receives data of a specific occupant. A seat cushion is designed from the occupant data. The seat cushion is provided with a cellular structure from the occupant data. Another method for manufacturing a seat cushion receives boundary conditions for a seat cushion. Applicable mechanical properties are determined for the boundary conditions of the seat cushion. Applicable thermal properties are determined for the boundary conditions of the seat cushion. A seat cushion is designed with a varying cellular structure to satisfy the applicable mechanical properties and the applicable thermal properties.

A method for manufacturing a seat cushion receives data of a specific occupant. A seat cushion is designed from the occupant data. The seat cushion is provided with a cellular structure from the occupant data. Another method for manufacturing a seat cushion receives boundary conditions for a seat cushion. Applicable mechanical properties are determined for the boundary conditions of the seat cushion. Applicable thermal properties are determined for the boundary conditions of the seat cushion. A seat cushion is designed with a varying cellular structure to satisfy the applicable mechanical properties and the applicable thermal properties.

A spool (100) of a linear string (110, 210, 310, 410) of pocketed springs is disclosed. The linear string of pocketed springs comprises springs (212, 312, 412) each provided in a textile pocket (214, 314, 414). The springs (212, 312, 412) comprise helically coiled steel wire springs. The textile pockets (214, 314, 414) are assembled to each other in linear direction. The linear string (110, 210, 310, 410) has a width of one textile pocket (214, 314, 414). The string (110, 210, 310, 410) of pocketed springs is present in the spool (100) spirally wound and in a compressed state such that the pocketed springs (212, 312, 412) can expand upon unwinding the string (110, 210, 310, 410) of pocketed springs from the spool (100).

A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Superimposed portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).

A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Superimposed portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).