Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A decking suspension material and method of application to a furniture frame is provided whereby in one embodiment a fabric is knitted from a plurality of polymeric yarns and at least one of the yarns has a relatively high denier. More specifically, a non-textured polyester warp yarn is utilized having a denier of 1,000 as contrasted to the other yarns which have a denier of 150. The high denier warp yarn consists of a multifilament yarn having a tenacity of 8.8 g/d, and a filament count of 74 whereby the multifilament yarn is exposed along the bottom surface of the fabric when installed on the furniture frame to provide strength and rigidity to the decking suspension material.

Abstract: A decking suspension material and method of application to a furniture frame is provided whereby in one embodiment a fabric is knitted from a plurality of polymeric yarns and at least one of the yarns has a relatively high gauge. More specifically, an elastomeric polyester warp yarn is utilized having a gauge of 35 as contrasted to the other yarns which have a denier of 150. The high gauge elastomeric warp yarn consists of a monofilament which is exposed along the bottom surface of the fabric when installed on the furniture frame to provide resiliency and strength to the decking suspension material.

Abstract: A process provides an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape and which eliminates unsightly underlines. A thick foam block is attached to a thin, rigid base and the assembly is placed in a mold whereby a thin foam cover is adhered to the foam block and to the outer edges of the base to produce a precisely contoured cushion which can be upholstered and fitted into a desired chair frame.

Abstract: A vacuum molding process for adhering a porous, foam-backed fabric 50 to a thermoplastic substrate 60 and for providing a nonplanar contour to the substrate 60 with fabric 50 adhered thereto. The porous, foam-backed fabric 50 is loosely positioned over a female mold 30. The substrate 60 is heated sufficiently for the substrate 60 to sag. The sagging substrate 60 is deposited over the female mold 30 in a manner whereby the substrate 60 contacts the fabric 50 around an effective mold perimeter 36. A vacuum applied through the female mold 30 is transmitted through the porous foam-backed fabric 50 and attracts the sagging substrate 60 into the mold 30. The attraction causes contact and adhesion of the heated substrate 60 and the foam-backed fabric 50.

Abstract: A tennis shoe outsole, a tennis shoe, the method of making the outsole and the method of making the tennis shoe. The outsole has a preformed abrasion-resistant insert therein in an outer region thereof. The method of making the outsole is by injection molding the outsole adherent to the insert which is held in position in an outsole cavity mold by indexing pins.