Abstract: A three-layered topper fora bedding or seating product has a first piece of foam, a second piece of foam and a pocketed spring comfort layer therebetween. The pocketed spring comfort layer has individually pocketed mini coil springs. At least one of the foam pieces may be infused with metallic particles to improve thermal conductivity. Alternatively, at least one of the foam pieces may be infused with microencapsulated phase change materials to improve heat absorption. At least one of the foam pieces may have a coating to further improve thermal conductivity or heat absorption.

Abstract: An apparatus for assembling a bedding foundation having spring modules and a frame includes a support configured to receive the frame, a bridge disposed over the support, and staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame. The apparatus also includes cameras coupled to the bridge and positioned over the support. Each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support. The apparatus also includes a driver configured to move the frame relative to the support and a controller in communication with the cameras and the driver, the controller configured to receive vision guidance signals from one of the cameras to direct movement of the driver and of the stapler operatively associated with the one of the cameras.

Abstract: Apparatuses, methods, and systems are disclosed for attaching structures. One system includes: a device having a first structure attached to a second structure; a first polymer coupled to the first structure, wherein the first polymer has a first temperature profile and a first shape; and a second polymer coupled to the second structure. The second polymer has a second temperature profile and a second shape. The second shape interlocks the first shape. The first polymer and the second polymer secure the first structure to the second structure in response to the first polymer and the second polymer being in a first temperature range. The first polymer and the second polymer release the first structure from the second structure in response to the first polymer and the second polymer being in a second temperature range different from the first temperature range.

Abstract: The seat heater control device is provided for a vehicle including a vehicle body, a vehicle seat and a seat heater. The seat heater control device includes: an electrostatic sensor provided in the vehicle seat and configured to measure capacitance between the electrostatic sensor and the vehicle body; and a controller configured to control an operation and/or an operational temperature of the seat heater, based on a measured value of the electrostatic sensor. The controller is configured to cause the seat heater to operate at a relative higher temperature when the measured value of the electrostatic sensor is higher than a first threshold and lower than a second threshold. The controller is configured to cause the seat heater to operate at a relative lower temperature when the measured value of the electrostatic sensor is higher than the second threshold.

Abstract: A method of making a vehicle seat assembly comprising providing a cushion having an “A” surface, a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, the cushion having a plurality of intrusions extending from the “A” surface towards the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 8% to 25%, securing the cushion to a frame, and covering cushion with a trim member.

Abstract: The invention relates to a method for manufacturing a sitting orthosis, which is provided with a contact surface where the user of the sitting orthosis makes contact with the sitting orthosis, from a representation of the contact surface of the sitting orthosis. The method comprises of manufacturing a shell part on the basis of the representation of the contact surface by machining processable material under the control of the representation of the contact surface of the sitting orthosis; and arranging a covering layer on the thus obtained shell part. The invention also relates to a sitting orthosis. The sitting orthosis comprises a contact surface where the user of the sitting orthosis makes contact with the sitting orthosis, wherein the sitting orthosis is assembled from a shell part of a material processable by machining and wherein at least the contact surface is provided with a covering layer.

Abstract: A foam reinforced and bent tube for use in a vehicle seat frame and a method of forming such a tube are provided. The tube has a cavity which extends along its length and at least one open end. The foam may be inserted into the cavity through any desirable process including, for example, injection. The bend is formed by heating a portion of the tubular element and bending it at the heated region. The insertion of the foam material into the cavity of the tubular element may precede, follow or be simultaneous with the heating and bending processes. The foam material may have a variable type and/or a variable density through the length of the cavity.

Abstract: A method for manufacturing a vehicle seat cushion assembly includes providing a first material to define an outer seating surface. A second material is sewn to the first material using first and second sewing lines disposed generally parallel to each other. A wadding material is disposed between the first and second materials and between the first and second sewing lines, and additional wadding material is disposed between the first and second materials adjacent to and not between the first and second sewing lines. The first and second materials are further sewn together using two additional sewing lines respectively disposed adjacent edges of the additional wadding material opposite the first and second sewing lines.

Abstract: A vehicle interior component including decorative stitching along a stitch path includes a seam spacer located between a component substrate and an overlying decorative covering. At least a portion of the seam spacer lies along the stitch path and supports the decorative covering therealong, where the covering may include a reduced thickness portion due to the decorative stitching. The seam spacer can have any number of configurations to prevent visual defects along the stitch path and/or to cause the appearance of simulated seams to be more realistic. The seam spacer may be attached to the covering at the same time the decorative stitching is sewn through the covering.

Abstract: A method and system that allows a user to create patterns for removable furniture covers employs a data input device to trace a piece of furniture. The data input device is traced over predetermined areas of the furniture known to those in the art of furniture cover design. The data input device transfers the trace data to a processor that renders an image of the traced portion of the piece of furniture. The processor permits the user to print off, or output to a cutter, appropriately shaped working patterns to cover the predetermined areas, and to assemble a removable furniture cover or slipcover for the piece of furniture.

Abstract: A seat assembly machine includes a plurality of grippers useful for securing a piece of trim to a seat cushion. In a disclosed example, each gripper includes a plurality of prongs that are moved between neutral, closed and released positions that each facilitate a different portion of the assembly process. In one example, each gripper includes a sleeve within which the prongs are moveable so that the prongs are manipulated between the neutral, closed and released positions. A disclosed example sleeve includes an interior channel having a contour that manipulates the prongs between the different positions based on the location of the prongs within the sleeve.

Abstract: Improved methods and apparatuses relating to installation of a sleeper mechanism into a frame of a sofa sleeper are disclosed. In one embodiment, initially the frame is aligned such that an open bottom portion of the frame is upright and facing outwardly. The sleeper mechanism is then advanced towards the open bottom portion and hook apertures on the brackets are engaged with upper fasteners on the frame. The sleeper mechanism is then swung inwardly towards the top portion of the frame until notches on the bracket are passed lower fasteners on the frame and then swung back towards the open bottom portion to engage the notches with the lower fasteners.

Abstract: In one embodiment, a mattress is constructed of a core having a first side and a second side. A padding layer is positioned at the first side of the core and has a contoured surface and a planar surface. A layer of individual fiberballs is disposed on the planar surface of the padding layer.

Abstract: Disclosed are tie down cord assemblies and methods of assembling same. According to some aspects, the tie down cord assembly includes a webbing having a tunnel portion and a flat portion, with the tunnel portion configured to receive a slotted cord and the flat portion configured to attach to fabric. The slotted cord weaves in and out of the tunnel portion and is configured to interact with a seat frame or other suitable structure to secure the fabric to a seat frame. The tie down cord assembly is configured to be universal so that it can be used with seat frames having different dimensions and/or configurations.

Abstract: Spring cushions 10 having slow-acting pocketed spring cores 12 characterized by the individual springs of the cores 12 being pocketed within semi-impermeable fabric material and a method of making such pocketed spring cores 12.

Abstract: A seat assembly machine includes a plurality of grippers useful for securing a piece of trim to a seat cushion. In a disclosed example, each gripper includes a plurality of prongs that are moved between neutral, closed and released positions that each facilitate a different portion of the assembly process. In one example, each gripper includes a sleeve within which the prongs are moveable so that the prongs are manipulated between the neutral, closed and released positions. A disclosed example sleeve includes an interior channel having a contour that manipulates the prongs between the different positions based on the location of the prongs within the sleeve.

Abstract: A seat assembly machine includes a plurality of grippers useful for securing a piece of trim to a seat cushion. In a disclosed example, each gripper includes a plurality of prongs that are moved between neutral, closed and released positions that each facilitate a different portion of the assembly process. In one example, each gripper includes a sleeve within which the prongs are moveable so that the prongs are manipulated between the neutral, closed and released positions. A disclosed example sleeve includes an interior channel having a contour that manipulates the prongs between the different positions based on the location of the prongs within the sleeve.

Abstract: A mattress material removal device for bedding mattresses comprising a fixed base member 15 in FIG. 4 with at least one side panel 4 and 5 in FIG. 1, at least one overhead portion 14 in FIG. 3 and at least one guide rail 2 in FIG. 1 adapted to secure and guide the mattress over the base member 15 as it moves through the removal device; at least one brush member 12 in FIG. 5 that makes contact with the top, bottom and side of the mattress; at least one suction member 6 in FIG. 5 positioned in close proximity to at least one brush member 12; at least one sprinkler device that is positioned in close proximity to the brush member 12; a conveyor mechanism 7 and 10 in FIG. 2 which is adapted to move the mattress so that it is in contact with the components of the removal device; a control device 16 in FIG. 5 that has at least one switch which is adapted to activate and de-activate one or more features of the mattress material removal device.

Abstract: A seat assembly machine includes a plurality of grippers useful for securing a piece of trim to a seat cushion. In a disclosed example, each gripper includes a plurality of prongs that are moved between neutral, closed and released positions that each facilitate a different portion of the assembly process. In one example, each gripper includes a sleeve within which the prongs are moveable so that the prongs are manipulated between the neutral, closed and released positions. A disclosed example sleeve includes an interior channel having a contour that manipulates the prongs between the different positions based on the location of the prongs within the sleeve.

Abstract: A cushion device that can be securely attached to a body of a user to, for example, aid in supporting a baby during feeding, and provide support of the neck, elbows, forearms and wrists of a wearer while engaging in an activity such as breast feeding. The cushion device supports the neck and back, and helps to hold the neck and back in an orthopedically correct position. The cushion device also relieves muscle stress associated with holding a baby by enabling the baby to be supported by the cushion. The cushion device is shaped to conform to the user's body and can be adjusted to have a fit of desired tightness so that the cushion device remains stably and securely in place on the wearer, the neck and back support of the cushion is enhanced, and the cushion device fits comfortably on the wearer.

Abstract: An apparatus and process for causing excess covering material at a workpiece corner to be gathered, folded and secured to a back side of the panel. A corner tucking apparatus includes a gathering plate positioned adjacent a positioning structure, and moves inwardly across the back side of the workpiece, from the corner, to gather and fold the corner flap. The gathering plate has a generally V-shaped notch which causes excess material to be gathered together as the plate moves inwardly. The gathered material upon reaching the apex of the notch is folded downwardly into contact with the back side of the workpiece. A securing structure which is carried inwardly with the gathering plate is then activated to fixedly secure the folded flap to the pad or workpiece.

Abstract: A method of manufacturing spring cushions (10) having slow-acting pocketed spring cores (12) characterized by the individual springs of the cores (12) being sealingly pocketed within semi-impermeable fabric material.

Abstract: The invention relates to the upholstery (2) of a seat element for a motor vehicle and to the method of creating it, in which method a foam support block (21) is produced to fit a frame element; a cover element (22) is created by cold-forming a foam sprayed onto a polypropylene substrate and attached on the reverse side of a textile material in the form of a skin or synthetic material to define the visible shape of the seat element; and the cover element is attached to the support block.

Abstract: The invention relates to a backrest (3) for a rear seat or a rear bench (1) of a motor vehicle, in particular a backrest (3) produced in accordance with a method according to one of the preceding claims, wherein the backrest (3) has upholstery (4) and a back plate (5, 5B) which is arranged behind the upholstery (4) and extends essentially over the entire backrest (3), wherein at least two thirds of the back plate (5, 5B) are composed of a rolled metal sheet.

Abstract: A device and method for producing functional pocket spring mattresses, and a mattress produced by the method, in which a predetermined number of pocket springs each prepared by connecting a predetermined number of pocket spring units to each other in the form of a band are arrayed to fit a bed mattress of a desired predetermined size.

Abstract: An aircraft passenger seat assembly as described herein is formed from two primary and modular components: a structural frame that provides passenger support and dynamic load paths for the seat assembly; and a comfort frame that provides the passenger seating surface and the external upholstery layer for the seat assembly. If the seat assembly is designed for multiple passengers, then a separate comfort frame is used for each passenger seat location. The structural frame can be formed as a molded composite construction, and the comfort frame can also utilize a molded composite support frame. The support frame is used as a mounting shell for a fabric carrier that includes the external upholstery layer. The modular design and use of composite materials results in a significant weight and parts count savings relative to conventional seat designs.

Abstract: The invention relates to a method for assembling a crash-active head support (1) of a vehicle seat, whereby the structure of the head support (1) is initially assembled from a rear and a front bearing shell and is then upholstered. The rear bearing shell (5) and the front bearing shell (11) are equipped with components (3, 15, 25, 31) and then the equipped bearing shells (5, 11) are rigidly connected together. An impact element (55) is coupled thereto thus forming a quadruple joint.

Abstract: The present invention relates to a vehicle seat frame made of structural foam having an attachment flange for attaching to a vehicle, and vehicle seat assembly, and methods of making the same. In at least one embodiment, the vehicle seat assembly comprises a seat frame made of structural foam and having a main body portion and at least one attachment flange depending from the main body portion. The attachment flange is attachable to a vehicle floor pan via an interference fit. The attachment flange has a first density and the main body portion has a second density, less than the first density. The vehicle seat assembly further comprises a cushion supported on the frame. The cushion is softer than the seat frame. The vehicle seat assembly further comprises a trim material disposed over the cushion and the frame.

Abstract: An aspect of the present invention relates to a method and system of receiving information of a user's support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user's requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user's firmness requirements.

Abstract: A spring mattress for beds is disclosed. In at least one embodiment, the spring mattress includes a plurality of strings which are interconnected side by side and include a continuous casing material with a plurality of separate pockets with coil springs enclosed therein. Moreover the casing material for at least some pockets is at least substantially airtight, thus providing a resistance to air being pressed out when the springs of the mattress are loaded, which, when subjected to a uniform load during a transition period, results in a gradually increasing depression of the spring to its depressed state. This results in a comfortable mattress, into which the user sinks gradually and which thus is comfortable and safe and allows the user to move easily. A corresponding method and device for manufacturing such a mattress are also described.

Abstract: A method for manufacturing a chair seat, wherein borders of the chair seat is injection molded by two steps, comprises following steps: a. preparing net cloth, inner border injecting mold, outer border injecting mold, plastic and gun screw; b. injecting inner border: warming up inner border injecting mold, simultaneously heating up the plastic, and injecting the plastic into the inner border injecting mold when its temperature reaches the injecting temperature; c. installing the net cloth: cutting out the net cloth according to the size of the inner border, impacting the edge of the net cloth into the inner border by the gun screw by hand, and then cutting redundant net cloth; d. injecting outer border: inserting the inner border with impacted net cloth into the outer border injecting mold, and injecting the plastic into the outer border injecting mold when its temperature reaches the injecting temperature.

Abstract: Mattresses and methods for processing a flexible foam material for use in a mattress to provide a mattress foam material that has more consistent firmness over time and area. The methods include pre-conditioning the foam pad or mattress by applying a force across a substantial portion of a major surface of the mattress to compress or stretch the height of the foam, the length of the foam, and/or the width of the foam to break or open closed cells. In certain embodiments, the force is applied by repeatedly pressing a platen against the foam pad or placing the foam pad between one or more rollers.

Abstract: A versatile support member constructed of a metallic mesh is provided in a bedding product. The support member is placed on top of the mattress core (whether foam or spring coil) before the mattress cover is attached. The support member may be constructed of titanium wire in a woven or welded mesh grid or web configuration, although other metals (such as, but not limited to, vanadium, chromium, platinum, molybdenum, nickel, iron, zinc), alloys thereof, or fiber composites (such as, but not limited to, carbon or graphite) may be used. The support member may be directly attached to the core or may be secured to the upper or lower border rods by hog rings, stitching, lacing, or other conventional means.

Abstract: A spring mattress is disclosed including a plurality of strings interconnected side by side, each string including a plurality of continuous casings and each casing including a coil spring. Further, in at least one embodiment, at least one of the casings in at least one of the strings includes a plurality of stretch openings into the interior of the casing, wherein at least some of said stretch openings are displaced in relation to each other in a lengthwise direction of the spring. At least one embodiment of the present invention also relates to a method and a device for manufacturing of such a mattress, as well as to a bed adapted for such a mattress.

Abstract: The present invention generally relates to an apparatus and a method used to upholster a box-spring frame. A textile tape with a portion encapsulating a draw cord is sewn to the inner perimeter of a border material. The other edge of the border material is sewn to a top cover material. The box-spring frame is placed within this assembly, with the top side of the frame abutting the top cover. This assembly is placed in the attachment apparatus. The attachment apparatus optionally compresses the box-spring frame and is equipped with a pair of tension applicators. Once in place, each of the two draw cord ends are secured to a corresponding tension applicator, and tension is applied to the draw cord. This tension tightens the border assembly edge around the frame. With the proper tension applied, the draw cord is secured to the box-spring frame. The bottom cover is then attached in the conventional manner with a series of staples.

Abstract: In one embodiment, a mattress is constructed of a core having a first side and a second side. A padding layer is positioned at the first side of the core and has a contoured surface and a planar surface. A layer of individual fiberballs is disposed on the planar surface of the padding layer.

Abstract: A method for the production of a fixing piece (12, 36) serves for fixing of covering material to cushion pieces for vehicle seats. A profile body (12) is connected to a separately produced sewn tag (36) which at least partly engages in a housing opening (34) in the profile body (12). The profile body (12) and the sewn tag (36), at least in the common jointing positions thereof, are predominantly made of plastic materials. According to the present invention, the known welding and glued connecting applications can be further improved such that the production method can be rapidly carried out with low production costs and without additional materials. A strong connection can be achieved, conforming to more stringent environmental aspects.

Abstract: An apparatus for bordering mattresses, comprising two mattress bordering assemblies, arranged at upper and at lower levels and provided with superimposed worktables being provided with mattress overturning devices, a mattress distribution assembly arranged upstream of the bordering assemblies to send the mattresses individually to the upper worktable or lower worktable, a chute arranged at the output of the worktable of the upper assembly and inclined to convey the mattresses bordered by the upper assembly toward a receiving table, the chute comprising actuatable movable elements, in order to allow the advancement of the mattresses from the upper worktable toward the receiving table.

Abstract: A device for mounting any type of seat covers (10) on foam cushion parts (12) of a seat, more particularly a vehicle seat, uses gripping elements (14) which form actuation groups (16, 18, 20, 22, 24) receiving the profiled strips (26, 28, 30, 32, 34) arranged on the seat cover (10). The gripping elements pull the profiled strips (16, 18, 20, 22, 24) into channel-like recesses (44, 46, 48, 50, 52) in the foam cushion part (12) by a positioning device (42). The positioning device allows a relative movement between the foam cushion part (12) and the corresponding gripping element (14) to fix the seat cover (10) to the foam cushion part (12).

Abstract: An apparatus for securing a trim cover to a foam pad includes a base and a platform coupled thereto that defines a working surface for supporting the foam pad thereon. A plurality of actuators project from the working surface. Each actuator is capable of movement away from and toward the working surface and includes a pair of retaining fingers capable of movement between an open and closed position. In use, the retaining fingers grasp a first connecting member on the trim cover and move the first connecting member toward the working surface as the actuators are moved toward the working surface so as to engage the first connecting member with a second connecting member in the foam pad thereby securing the trim cover to the foam pad.

Abstract: A center console 20 is formed by covering a console main body 35 by a skin main body 31 having a joined portion 37 where end portions of an upper surface skin material 31a and a side surface skin material 31b are joined together. On the skin main body 31, core members 38, 39 are provided along the joined portion 37, and a recessed portion 35a formed in an edge portion of the console main body 35 and a raised portion 37a formed by the core members 38, 39 on the side of the skin main body 31 are fitted on or in together.

Abstract: An office chair is provided having a contoured back assembly comprising a back frame and a suspension fabric. The fabric is attached to the back frame about its periphery wherein the back frame has a three-dimensional contoured shape formed by overlapped frame rings with the fabric being joined thereto. The fabric is secured to the frame by a machine wherein the fabric is first stretched from the outer edge of the fabric and then is clamped by a front frame section in the pre-tensioned or pre-streched condition. The fabric edges are allowed to hang loose and then fixed in the front frame section. Once secured, the fabric is unclamped from the front frame section, and then this sub-assembly is affixed to the rear frame ring to complete the assembly of the back frame.

Abstract: An article of furniture, for example a chair, is upholstered with a sports jersey for displaying the jersey thereon. The front side and logo of the jersey are displayed on the back supporting surface of the chair while the rear side and player number of the jersey are displayed on the seating surface of the chair. The chair arms are upholstered with arms of the sports jersey. By providing a chair upholstered with a sports jersey conventional, authentic and readily available sports equipment can be reused in a practical way and displayed in an aesthetically pleasing manner.

Abstract: A mattress frame that occupies a small volume and can be used by a recipient without having to assemble the frame. The frame has four connected sides and is made of foam. The frame is rectangular in shape and has two longer sides and two shorter sides. The two shorter sides are folded in a U shape so that a bow-tie-shaped frame results. The bow-tie-shaped frame is rolled and packaged in a container. The frame can be rolled to form a spiral or an M-shape. A recipient of the rolled frame removes the frame from its packaging and the frame expands to its intended shape.

Abstract: A head restraint assembly comprising a frame assembly including a retention member. A pillow coupled to the frame assembly with the pillow configured to allow access to the retention member. A cover assembly having a back end and a front end envelopes and conforms to the shape of the pillow with the cover assembly including a flat strip member coupled to the back end and a barb strip member coupled to the front end of the cover assembly. The flat strip member and the barb strip member couple with each other in the retention member closing the cover assembly over the pillow. Also, a method for making a head restraint assembly.

Abstract: There is disclosed a method of manufacturing an insert suitable for placement within a seat of an automotive vehicle. The insert preferably includes multiple layers, one of which includes a heater for providing an occupant of the seat with warmth. The insert also preferably includes a blower or air pump for providing ventilation and/or cooling to the seat occupant.

Abstract: An apparatus for facilitating assembling of a covering sheet onto a cushioned padding for a seat, the covering sheet being formed into a three-dimensional shape and having tensioning cords provided therein, the cushioned padding having a central portion, bulged portions formed at both sides of the central portion, and grooves formed in the central portion, the tensioning cords of the covering sheet being to be received in the grooves of the cushioned padding at the time of fastening of the covering sheet to the cushioned padding, and being to be fastened to the cushioned padding, the apparatus including a base table, a supporting member mounted on the base table for receiving and supporting the cushioned padding at the time of the assembling of the covering sheet onto the cushioned padding, hooking arms arranged at both sides of the base table for causing the bulged portions of the cushioned padding on the supporting member to be pulled away from each other and causing the grooves of the cushioned padding to

Abstract: An attachment structure for a load-bearing fabric including an expandable carrier secured to an un-stretched load-bearing fabric. To attach the carrier to a support frame, the carrier and fabric are stretched together to desired shape and secured to the frame. An indexing system registers the carrier and frame and optionally stretches the fabric a predetermined amount. The present invention also provides a lip that flexes in one direction and maintains the fabric in a stretched condition in another. A tool that joins the carrier and frame generally includes a drive roller and a primary roller adapted to move toward one another and join a carrier and the support frame disposed therebetween. The tool may include alignment rollers near the primary and drive rollers to track along and align the carrier and frame.

Abstract: In one embodiment, a method for making a pillow comprises cutting at least one piece of fabric to form a pair of skins that each comprise a midsection and two arm sections. The two skins are sewn together near their outer edges except for a portion of the mid section to form a shell defining and interior and having a middle region with an opening into the interior and two opposing arms extending from the middle region to form a well region. A fill material is blown into the interior of the shell until the pillow has a firmness defined by an IFD of at least about 20 Newtons with 25% deflection, and the opening in the middle region is closed.

Abstract: An apparatus (1) is described for upholstering components of chairs, armchairs, or the like, in particular backrests and/or seats having a sandwich structure (11) with a covering layer (12) fitted so as to cover a frame (14) at least partially, the apparatus comprising at least one stapling gun (8), a support table (10a) for the sandwich structure (11), means (16) for compressing the sandwich structure (11), and a robotic arm (4) on which the stapling gun (8) is mounted, as well as means for controlling the robotic arm (4), the control means being arranged to guide and operate the stapling gun (8) along a stapling path defined peripherally on the sandwich structure (11).