A method for forming a three-dimensionally (3D) printed flexible support apparatus includes: producing arrays of V-spring elements using a 3D printing system, each array including a plurality of V-spring elements arranged in a predefined array shape, and each V-spring element having a predefined firmness or hysteresis characteristic; arranging the arrays of V-spring elements in at least one two-dimensional (2D) array grid using the 3D printing system, such that at least one V-spring element of each array is attached to a V-spring element of at least one adjacent array; and shaping the at least one array grid according to a predefined volume to form the support apparatus.

A method of making a foamed article comprises (a) milling a block or sheet of thermoplastic polymer to form a precursor; (b) crosslinking the thermoplastic polymer; (c) heating the precursor to a first temperature to soften the thermoplastic polymer; (d) infusing the thermoplastic polymer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymer; and (e) while the thermoplastic polymer is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

Extractor systems for extracting a flexible article of manufacture from a mold include an extraction roller, at least one track configured to support the extraction roller, and a trolley configured to carry the extraction roller from a first side of the mold toward a second, opposite side of the mold. Molding systems include a mold and an extractor system. Methods of extracting a flexible article of manufacture from a mold include separating a first platen and a second platen, positioning an extraction roller between the separated first and second platens, engaging the article of manufacture with a row of teeth positioned along the extraction roller, and rotating the extraction roller to wrap the article of manufacture about the extraction roller.

A method of making a sleep product having a cooling gel layer includes providing a mold, coating the mold with a composite material including a mold release and a cooling gel, and introducing a foaming mixture into the mold so that the foaming mixture is in contact with the composite material. The foaming mixture is allowed to rise and cure into a foam layer having an outer surface covered by the composite material. The composite material is both a mold release coating that facilitates removing the foam layer from the mold and a cooling gel coating that remains on the outer surface of the foam layer after the foam layer has been removed from the mold to provide a cooling effect at the outer surface of the foam layer.

A process and apparatus for manufacturing a mattress generally includes an automated foam layer placement apparatus for accurately securing one or more foam layers onto an innercore unit and bucket assembly.

A foam seating article includes a layer of molded foam surrounding a hollow shell made of hard plastic. A fabric covering encloses the shell and molded foam. The foam seating article can take the form of a chair, stool, sofa, chaise lounge, bench or Ottoman. The hollow shell can be formed using blow molding, injection molding or by capping both ends of a tube with disks. Air pressure inside the airtight hollow shell prevents the shell from collapsing inwards under the weight of an occupant. Alternatively, the hollow shell of the seating article can be accessed through a removable lid. The seating article includes no wood or metal. The layer of molded foam includes sections of different foam types, such as high density (HD) foam, memory foam and latex foam. Molding foam around a hard plastic shell is simpler and less costly than making conventional metal or wood framed furniture.

A station for detecting, controlling, checking, and comparing physical parameters of a mattress or a pillow, includes a retention frame for a resting surface, designed to support the mattress or the pillow. The resting surface, at one of its corners, includes respective abutment walls for concurrent side faces of the mattress or the pillow. The frame also supports at least one rangefinder which is aligned with at least one face of the mattress or the pillow that lies opposite the respective faces that rest on the resting surface and against the walls.

Method and apparatus for deconstructing, cutting, shredding or disintegrating a mattress, sofa, car seat or similar items with steel or metal sub frames by the use of high pressure water jets whereby the mattress, sofa, car seat or the like is compressed and then deconstructed while compressed by the use of high pressure water jets.

The present invention relates to a method for welding a 3D bellows. The method includes: repeatedly laminating a unit cell material, a second adhesion-preventing film, a different unit cell material, and a first adhesion-preventing film; forming ventilation holes on the unit cell materials by pressing a hole-processing cutter on which a hole-circumference welding heater is installed onto the laminated unit cell materials and the first adhesion-preventing films, and then heating the circumference of the ventilation holes; finishing two sides of the unit cells by positioning, on two outermost surfaces of the laminated unit cell materials, a first finishing unit cell material and a second finishing unit cell material provided with an air injection port; and cutting the first finishing unit cell material, the unit cell materials, and the second finishing unit cell material and heating the periphery of the cut area by pressing a contour-processing cutter.

An automated system and method are disclosed for producing an inflatable product having a first sheet, a second sheet, and a plurality of tensioning structures between the first and second sheets. The system includes an upstream tensioning structure production subsystem that produces the tensioning structures and a downstream preassembly production subsystem that couples the tensioning structures to the first and second sheets. The subsystems may operate simultaneously to produce the inflatable product in an automated, efficient, and repeatable manner.