Systems and methods for cushion supports

摘要

The mattress assemblies have an array of springs extending from a sheet. Each spring in the array may be manufactured by choosing a position for the spring, cutting a profile of the sheet spring in the sheet, peeling back or bending the profile or tab of the sheet, and shaping the profile to form the sheet spring. The array of springs may be formed from creating a plurality of such springs along rows and columns. In certain embodiments, multiple sheets may be stacked to form the sheet spring array.

主权项

1. A method of manufacturing a sheet spring innercore, comprising:
providing a first metallic sheet; and forming a first plurality of sheet springs in the first metallic sheet member, each one of the first plurality of sheet springs having an adjacent opening and each one of the first plurality of sheet springs having a serpentine shape, wherein each one of the first plurality of sheet springs has one end integral with the first metallic sheet and a free terminal end, each one of the first plurality of sheet springs extending along a longitudinal axis being perpendicular to the first metallic sheet, each one of the first plurality of sheet springs being compressible along the longitudinal axis in response to a force applied along the longitudinal axis, wherein each one of the first plurality of sheet springs having the serpentine shape are oriented identically on the first metallic sheet member.