Abstract: Cushions such as seat cushions, mattresses, and the like include a chassis core. The chassis core includes a rigid or semi-rigid base sheet; and a plurality of paired flat springs coupled to the rigid or semi-rigid base sheet, wherein each paired flat spring comprises a lower flat spring including a first terminal end, a second terminal end, and a flexible arcuate member extending from the first terminal end to the second terminal end, and an upper flat spring including a first terminal end, a second terminal end, and a flexible arcuate member extending from the first terminal end to the second terminal end, wherein the first and second terminal ends of the upper flat spring are fixedly attached to respective first and second terminal ends of the lower flat spring such that the upper flat spring is inverted relative to the lower flat spring. Also disclosed are processes for manufacturing the core chassis.

Abstract: A plunger matrix mattress includes a number of independently movable foam padded plungers that form an array of independently movable points of support. This type of mattress significantly improves body contouring over conventional coil spring mattress designs. The plunger matrix mattress also allows substantial airflow through the mattress improving over conventional foam mattress designs. Different plungers may have different spring and dampening characteristics to allow different plungers and plunger zones of the mattress to exhibit different firmness levels. Individual plungers may be removed and replaced independently, for example to replace the plunger with another plunger with a different spring characteristic, and make other types of adjustments and repairs.

Abstract: A plunger for a matrix mattress includes a pin guide having a flange and a guide body extending from the flange. A pin slidably received within the pin guide includes a flange located above the flange of the pin guide and a shaft extending from the flange through the guide body. The flange of the pin carries a deformable head. A tension spring has a first end fixed to the guide body and a second end located below the guide body positioned to receive a bottom end of the pin shaft. The spring is configured to resiliently stretch with downward motion of the pin with respect to the pin guide. A dampening device captured around the shaft of the pin between the flange of the pin and the flange of the pin guide resiliently deforms with downward motion of the pin with respect to the pin guide.

Abstract: Cushioning articles such as mattresses can include a three dimensional wave spring core. The wave spring includes a polymeric lattice spring structure including a plurality of alternating layers stackedly arranged to define a height of the wave spring, wherein each one of the alternating layers is defined by a single strand having one or more upward and downward undulations, wherein the alternating layers are arranged such that an upward undulation of one layer is connected to a downward undulation of the other layer to define a cell configured to receive a compressive force, wherein the lattice structure has a sinusoidal shape when viewed top down and is configured to have three dimensional structure.

Abstract: A dual-spring plunger for a plunger matrix mattress assembly includes an outer tension spring with an upper end fixed to an outer spring mount of a plunger guide body and a lower end located below the guide body positioned to receive a bottom end of a pin of the plunger. An inner tension spring nested within the outer tension spring has an upper end fixed to the inner spring mount of the guide body and a lower end having a spur slidably captured within a slot through a fin of the shaft of the pin. The outer spring is tensioned while the inner spring is not tensioned during a first portion of downward movement of the pin relative to the pin guide, whereas both the outer and the inner spring are tensioned during a second portion of downward movement of the pin relative to the pin guide.

Abstract: Mattresses including a chassis core including a rigid or semi-rigid base sheet; a plurality of flat springs spaced apart from one another in parallel rows, wherein each one of the plurality of flat springs comprises a first terminal end, a second terminal end, and a flexible arcuate member extending from the first terminal end to the second terminal end, and wherein a center of an arc defined by the arcuate member is fixedly attached to the rigid base sheet; a body support disk disposed on each one of the first and second terminal ends. The body support disk supports the load of an individual. In some embodiments, the body support disk is pivotably connected to each terminal end.

Abstract: A progressive spring coil comprises a first spring portion comprising a top end and a bottom end and having a first spring rate, wherein the first spring rate is substantially linear or substantially nonlinear; a second spring portion comprising a top end and a bottom end and having a second spring rate, wherein the second spring rate is substantially linear or substantially nonlinear; and a third spring portion disposed between the first spring portion and the second spring portion, wherein the third spring portion has a third spring rate, wherein the third spring rate is substantially linear or substantially nonlinear.

Abstract: A plunger matrix mattress includes a number of independently movable foam padded plungers that form an array of independently movable points of support. This type of mattress significantly improves body contouring over conventional coil spring mattress designs. The plunger matrix mattress also allows substantial airflow through the mattress improving over conventional foam mattress designs. Different plungers may have different spring and dampening characteristics to allow different plungers and plunger zones of the mattress to exhibit different firmness levels. Individual plungers may be removed and replaced independently, for example to replace the plunger with another plunger with a different spring characteristic, and make other types of adjustments and repairs.

Abstract: A dual-spring plunger for a plunger matrix mattress assembly includes an outer tension spring with an upper end fixed to an outer spring mount of a plunger guide body and a lower end located below the guide body positioned to receive a bottom end of a pin of the plunger. An inner tension spring nested within the outer tension spring has an upper end fixed to the inner spring mount of the guide body and a lower end having a spur slidably captured within a slot through a fin of the shaft of the pin. The outer spring is tensioned while the inner spring is not tensioned during a first portion of downward movement of the pin relative to the pin guide, whereas both the outer and the inner spring are tensioned during a second portion of downward movement of the pin relative to the pin guide.

Abstract: A plunger for a matrix mattress includes a pin guide having a flange and a guide body extending from the flange. A pin slidably received within the pin guide includes a flange located above the flange of the pin guide and a shaft extending from the flange through the guide body. The flange of the pin carries a deformable head. A tension spring has a first end fixed to the guide body and a second end located below the guide body positioned to receive a bottom end of the pin shaft. The spring is configured to resiliently stretch with downward motion of the pin with respect to the pin guide. A dampening device captured around the shaft of the pin between the flange of the pin and the flange of the pin guide resiliently deforms with downward motion of the pin with respect to the pin guide.

Abstract: A progressive spring coil comprises a first spring portion comprising a top end and a bottom end and having a first spring rate, wherein the first spring rate is substantially linear or substantially nonlinear; a second spring portion comprising a top end and a bottom end and having a second spring rate, wherein the second spring rate is substantially linear or substantially nonlinear; and a third spring portion disposed between the first spring portion and the second spring portion, wherein the third spring portion has a third spring rate, wherein the third spring rate is substantially linear or substantially nonlinear.

Abstract: Systems and methods include a spring-coil assembly having non-linear load-deflection characteristics that are substantially similar to foam. In particular, the systems and methods described herein include a first set of encased springs that are in a partially compressed state and a second set of shorter springs. These two sets of springs may be arranged in alternating rows such that the resulting spring-coil assembly displays non-linear load-deflection characteristics similar to foam.