Abstract: A mattress having an inverted top panel/border seam, with an optional appended decorative rope welting on the border is described. An inverted seam secures the top panel to the border portion of a mattress cover to eliminate bumps and creases found in conventional welted top seam. Manufacturing costs may be reduced by eliminating the need for an expensive table-mounted tape edge closure machine and/or skilled operators, since the inverted seam may be flay sewn with a conventional sewing machine or even hand-stitched. Alternatively, a conventional tape edge machine can be used with less-skilled labor and or reduced tape/welting material, as all of the stitches and welting are hidden inside the mattress by the inverted seam.

Abstract: A pillow top mattress is made by first sewing a mattress core border to respective pillow top borders, forming mitered corners on each, then pulling the combined borders over the mattress core, securing the combined borders to the core material, and then adding pillow top insulation and sewing a pillow top panel to the free edge of each pillow top border.

Abstract: A bedding or seating product comprising a spring assembly made up of a plurality of parallel strings of springs joined to each other. Each of the strings of springs comprises a row of interconnected pocketed coil springs. Selected pockets of fabric are shorter than adjacent pockets, so coil springs in the selected pockets are under a greater load than adjacent coil springs. In one preferred embodiment, every other pocket is under a greater load than the adjacent pockets, resulting in a checkerboard arrangement in at least one area of the product.

Abstract: A mattress having an inverted top panel/border seam, with an optional appended decorative rope welting on the border is described. An inverted seam secures the top panel to the border portion of a mattress cover to eliminate bumps and creases found in conventional welted top seam. Manufacturing costs may be reduced by eliminating the need for an expensive table-mounted tape edge closure machine and/or skilled operators, since the inverted seam may be flay sewn with a conventional sewing machine or even hand-stitched. Alternatively, a conventional tape edge machine can be used with less-skilled labor and or reduced tape/welting material, as all of the stitches and welting are hidden inside the mattress by the inverted seam.

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).

Abstract: The apparatus has an indexable carriage adapted to move the coil springs and the border wire along a path. A wire cutter disposed adjacent the path has an inner member with an axial hole adapted to receive the wire and a tubular outer member receiving the inner member and movable relative to the inner member. The outer member has a cutting edge. An actuator is operatively connected to one of the inner and outer members to provide a relative rotation between the inner and outer members. That relative rotation results in the wire being sheared by the cutting edge to provide a length of wire. A wire wrapping mechanism disposed adjacent the path receives the length of wire and wraps the length of wire around an end turn of a coil spring and a border wire.

Abstract: An automated method for installing a seat cover and a device for implementing the method are disclosed. The seat cover is provided with at least one shaped spar onto a seat body that includes at least one securing element which is positioned in the base of at least one slot in the seat body and into which the shaped spar may be secured.

Abstract: A method and apparatus for forming spring units for use in a mattress, bed, divan bed, or other upholstered unit, the method including the step of inserting a second spring (12A) into a first spring immediately prior to said first spring being formed into a pocketted spring. The second spring (12A) may be formed into a pocketted spring prior to insertion into said first spring. The apparatus includes means (4) for feeding a second spring (12A) to a composite spring forming station (6) immediately prior to a first spring being fed to said station, means to compress and rotate the formed composite spring (30) through substantially 90°, means to insert the composite spring into a sleeve of material, and means to form said composite spring and a portion of said sleeve into a pocketted spring unit.

Abstract: A seat assembly machine that uses stanchion rods to install flexible covers on seat cushions characterized by the fact that the stanchion rods are slidably mounted via slides in an axis generally perpendicular to the stuffing or plunging axis such that the stanchion rods more closely follow the contour of the seat cushion. The present invention can be applied to either bottom seat cushion stuffers, back rest stuffers or neck cushion stuffers as desired. In the preferred embodiment the combination of a cam mechanism and spring mechanism controls sliding movement of the stanchion rods. The cam mechanism includes a cam track having an eccentric substantially matched closely to the contour of the intended seat cushion and a follower adapted to follow the eccentric.

Abstract: A system and method for manufacturing pocketed compound nested coil springs includes inserting a compressed, preferably pocketed, smaller coil spring into a vertically oriented larger coil spring either prior to compressing and inserting the outer coil spring into pocket material or after the larger coil spring has been compressed and prior to being encapsulated in the pocket. Alternative systems and methods are also contemplated which include forming the outer coil spring around the inner coil spring and pocketing the resulting nested spring unit.

Abstract: The invention relates to a spring mattress comprising a plurality of interconnected coil spring elements, whereby the mattress includes at least two layers extending in parallel with the plane on the mattress and each exhibiting different properties of resilience. The feature characterizing the mattress in accordance with the invention are that the same coil springs extend across both the layers and that these coil springs exhibit a higher degree of bias only along part of their extension, thus forming the layers exhibiting different properties of resilience.

Abstract: A skin for an automotive interior trim panel is provided comprising a first skin portion and a second skin portion. First skin portion comprises a receptacle and a second skin portion comprises a protrusion. When connected, a portion of the protrusion in mechanical engagement with a portion of the receptacle to join the first skin portion and the second skin portion.

Abstract: A seat assembling machine commonly known as a skinner or stuffer is adjustable in several axes to allow the machine to be adjusted for different sizes/configurations of seats and seat covers. The machine includes a carriage which is driven towards a padded seat frame. The carriage includes a plurality of generally parallel stanchion rods that can be selectively spaced apart along two different perpendicular axes to receive a selected size of seat cover. The machine inserts a seat cover outside out over padded seat frames. The carriage may selectively rotated, selectively translated forward or horizontally and selectively tilted to better align the stanchion rods with the padded seat frame.

Abstract: A method of assembling strings of pocketed coil springs into an innerspring core which may be used as the core of a mattress, cushion or similar body support foundation uses plastic netting reinforced nonwoven webs supplied between a pair of spaced apart heated rolls. Strings of pocketed coil springs are fed in seriatim into the nip between the rolls to heat the netting and activate an integral adhesive to bond the webs to the top and bottom surfaces of the pockets of each string. The core formed thus has reinforced webs on the top and bottom of the strings. The process overcomes the problems encountered when hot melt spraying is utilized to bond the pocketed coil strings together.

Abstract: The apparatus takes coil springs and sequentially forms fabric pockets around the coil springs to form a string of pocket coil springs. It includes a system for forming a length of folded fabric for movement on a frame, a split cylinder which moves to an inclined position to receive a coil spring and then to a generally vertical position to locate the coil spring on a support member and to allow a compressing member to extend through the gap of the split cylinder to compress the coil spring. An inserting device is employed to insert the compressed coil spring between the folded layers of the length of folded fabric which then is moved on the frame to bonding units to allow an edge bond and transverse bonds to be made to form a pocket around each coil spring. The bonding units includes of two stationary ultrasonic bonding devices fixedly located below the length of folded fabric with movable anvils located above the length of folded fabric which are employed for carrying out the bonding operations.

Abstract: An inner body panel that is configured to receive a snap-in component and a corresponding method of manufacture are provided. The inner body panel includes a urethane layer having an inner molded edge defining a first aperture and a glass mat layer affixed to the urethane layer. The glass mat has a second aperture that is smaller than the first aperture. The inner body panel also includes a cloth layer affixed to the glass mat layer that has a third aperture that is smaller than the first aperture. The cloth layer and the glass mat layer are trapped between the inner molded edge and the snap-in component, whereby a soft gasket fit between the snap-in component and the inner molded edge is produced and damage to the inner body panel is minimized when the snap-in component is inserted into the inner body panel.

Abstract: A method and apparatus for basting layers of flexible materials together such as for quilt making includes a spacing member, such as a grid, having openings therein is disposed on a support surface. A backing member or first flexible member is operatively secured to the support surface and a second member disposed over the first flexible member. Other layers are then placed over the second flexible member and, in the case of quilt making, there would typically be just three layers. A basting gun having a hollow needle is then utilized by pushing the hollow needle through all of the layers of flexible material and into one of the openings in the spacing member. Then the basting tool is utilized to force the first end of the plastic fastener through the hollow needle so that this first end of the plastic fastener is on one end of the flexible members and the second end of the plastic fastener is on the other side of the flexible members whereby the flexible members are held together by the plastic fastener.

Abstract: A system for automatically connecting a seat back to a seat cushion to assemble a seat, which includes a first setting device for setting the seat back upright, a second setting device for setting a seat cushion horizontally, and a robot hand device. The seat back is easily set on the first setting device, with a part of its upholstery being turned up by a retaining element of the same first setting device to expose the associated connecting member. The robot hand device includes a pressure arm element to pressingly hold such turned-up part of seat back upholstery. The seat back is transferred by the robot hand device to the second setting device, maintaining such turned-up state of the upholstery part all the way, so that the exposed connecting member of seat back is connected to another connecting member of seat cushion by operation of an automated connecting device of said second setting device, thereby forming a resulting seat.

Abstract: The present invention is a highly predictable composite usable to fabricate such structural articles as complex-shaped automotive body parts and building panels. Included in this composite is at least one netlike preform having a plurality of inter-crossed roving bound to each other at thermoset junction points. This preform is compressed into a mold, and at least one layer of polymer paste is added thereto. The preform layers and the polymer paste layers are compressed to the shape of the mold, and then they are heat and flame treated to complete the curing of the thermoset resin and to produce a desired surface finish.

Abstract: It is provided with a longitudinal bearing (2) mounted on a frame (1) and framed by two side, vertical and parallel guides (9) and (10), the position of the latter being adjustable in order for the spacing thereof to match the thickness of the spring carcass, which is hauled by a thruster (4) driven by a motor reducer (5) intermittently towards the working area of two stapling heads (12-12) where a retractable ram (15) receives the spring action directly and adjusts, in accordance with the latter's diameter, the position of the balance lever acting on the proximity detector that in turn controls the movement of the motor reducer (5) in order for each spring to duly face the stapling heads (12).

Abstract: A seat skinning mechanism for skinning a flexible membrane cover on a polymeric foam vehicle seat body is provided which, in a preferred embodiment, includes a first support surface for positioning the seat body located generally underneath the seat body, a second support surface contacting the seat body on a first vertical side of a seat body, first and second powered wings pivotally mounted with respect to the second support surface, the wings causing the lateral edges of the seat body to fold upon themselves to an extent to allow the flexible membrane cover to be placed over the foam body, the second support surface and the wings, and a lift to force the foam body upward, removing the seat body from between the second support surface and the wings with the membrane cover on the seat body.

Abstract: An automobile sun visor has a visor body, an internal structural member arranged in the visor body and having shorter sides, a retaining clip attached to one of the shorter sides of the internal structural member and having arms provided with front edges which are flush with an outer surface of a side of the sun visor body, and a longitudinal bag-shaped sheath which covers an outer surface of the visor body and has a free end which forms a joint line on the front edges of the arms of the retaining clip.

Abstract: A mechanism for attaching an outer covering to a molded shell-type vehicle sun visor having a pair of shell halves and an aperture in one shell half. The mechanism includes a stackes attached to or integral with an inner surface of the shell half and a bezel which cooperates with the stakes to sandwich the free edge portions of the covering along an inner surface of a shell half around the aperture to prevent the covering from working loose.

Abstract: Seat covers are sewn inside-out and then inverted to fit over a frame. Inversion is accomplished by threading the sewn seat cover over a pair of generally parallel arms. The sewn seat cover is generally in the form of a pocket. The closed end of the pocket is engaged by the blunt edge of a plate. The plate pushes the closed end between the arms forcing the structure of the pocket to ride up and over the top of the arms and downward between the two arms thereby inverting the seat cover to a right side out condition.

Abstract: Seat covers are sewn inside-out and then inverted to fit over a frame. Inversion is accomplished by threading the sewn seat cover over a pair of generally parallel arms. The sewn seat cover is generally in the form of a pocket. The closed end of the pocket is engaged by the blunt edge of a plate. The plate pushes the closed end between the arms forcing the structure of the pocket to ride up and over the top of the arms and downward between the two arms thereby inverting the seat cover to a right side out condition.

Abstract: A method of making a pillow which has padding as well as an inflatable insert which starts with two integral and identical pieces of cloth and is particularly efficient in terms of the amount of labor and the type of equipment required to produce a high-quality article.

Abstract: A machine for inserting foam cores within the coil springs of a mattress or similar device having a series of spiral coil springs. The machine has a series of hollow receptacles for accommodated the cores above and aligned with one row of coil springs of the mattress. Beneath the mattress, a series of grippers is located in alignment with the receptacles. When actuated, the grippers rise through the coil springs, grip the bottom of each foam core, and return through the coils, placing each core in the center of each of the coils of the row of coils. The mattress is then indexed, and the process repeated for the next row of coils.

Abstract: The border of a mattress or other such coil spring assembly is stabilized and reinforced using a continuous length of resilient rope which is wedged between convolutions of adjacent springs a plurality of turns about the perimeter of the coil spring assembly.

Abstract: An automated process and apparatus for the production of innerspring mattresses having an innerspring situated between top and bottom frame members. A microprocessor controlled apparatus forms the frame members and arranges them for transportation to a clamping table. A first frame member is fed to the clamping table. An innerspring is then fed to the clamping table where it is clamped to the first frame member around the periphery thereof, thereby forming a first combination. The first combination is then removed from the clamping table and a second frame member is fed to the clamping table. The first combination is then turned over and fed back to the clamping table where it is then clamped to the second frame member, thereby forming a completed innerspring mattress.

Abstract: The mattress assembly installation has a number of mattress padding material spools for supplying separate mattress padding materials. These materials are received and superposed in a receiving stage downstream of the spools. The mattress padding material portion is cut at a cutting station from the supply of materials. Subsequently, or at the same time, a gluing apparatus, which may be part of the cutting apparatus, deposits strips of adhesive on the superposed mattress padding materials. The materials are conveyed to a folding station where at the materials are folding above a spring frame together with an inverted mattress covering. A robot or a carriage is provided for moving, inverting and removing the spring frame from the folding station.

Abstract: An apparatus for forming a seat comprising an upper die member, an intermediate die member, and a lower die member on which is placed a trim cover assembly. The intermediate die member has, formed at its inner lower area, a projection which is to close the recess of a valley or slope created in the retained area of the trim cover assembly where the upper die member is pressed against and collapses the peripheral end areas of the trim cover assembly placed on the lower die member. Further, a second projection is formed above such first one within the intermediate die member in order to from a recess in a resultant foam cushion member integral with the trim cover assembly so that a sewn jointed point and terminal end of the trim cover assembly are received in such recess, which permits a side wall portion of the trim cover assembly to be stretched neatly long the corresponding portion of the cushion member.

Abstract: A device for automatically securing a borderwire on a mattress innerspring comprising a plurality of coils is disclosed. The device comprises a tool for sequentially joining segments of the borderwire to perimeter ones of the coils located along a perimeter of the innerspring, apparatus for advancing the mattress innerspring and borderwire toward the tool, a conductive element for sequentially contacting the perimeter ones of the coils, a sensor for detecting contact of the conductive element with the perimeter ones of the coils, and a control responsive to the sensor for actuating the tool.

Abstract: The subject invention provides a method and assembly (10) for upholstering a foam cushion (16) with fabric (12, 14). A locator strip (10) accurately positions the fabric (12) upon the cushion (16). The locator strip includes an array of U-shaped pockets (30) along one edge which are separated by finger-like projections (32). A thin fracturable filament (40) is fixedly attached to the distal end (34) of the projections (32) to enclose the pockets (30). The locator strip (10) is sewn between the edges (18, 20) of two fabrics (12, 14) with thread (36) stitches passing through the pockets (30) and around the projections (32). The locator strip (10) functions to guide the edges (18, 20) of the two fabric covers (12, 14) into an elongated slot (22) in the cushion (16).

Abstract: Disclosed is a method of making a seat-like object comprising a leather touch surface layer and a urethane cushion body stuck together. It uses a weld sheet intervening between the surface layer and the cushion body in place of application of an adhesive substance to the surface layer and the cushion body. The weld sheet when heated above its melting temperature, will weld and stick the surface layer and the cushion body together, maintaining the leather touch over the whole surface area of the product, still allowing air to pass in or out.

Abstract: An improved method and apparatus for constructing an improved pocketed coil string, in which a tube of fabric is formed, a transverse seam is provided across the tube, a partially compressed coil spring is inserted adjacent to the seam, and a second seam is provided, thus encapsulating the spring. The fabric is guided around the outer surface of a tubular mandrel, thus forming a tube, and the spring is inserted into the mandrel such that as the spring exits the opposite side of the mandrel, it is within the tube of fabric. Excessive spring compression is avoided.

Abstract: Apparatus for automatically securing borderwires on mattress innersprings, including a support member for maintaining a mattress innerspring and borderwires on edge in a substantially upright position as clips are automatically wrapped along the supported edge on each side thereof. A rotatable paddle-like member is provided for rotating the mattress innerspring and the borderwires on the support member to present another edge on which clips are to be wrapped. Control means is provided for carrying out, automatically, each operation performed by the apparatus.

Abstract: Apparatus for automatically wrapping clips on the borderwires and coils of a mattress innerspring which includes an adjustable alignment mechanism and adjustable clip wrapping tool mechanism for enabling the apparatus to accommodate borderwires and mattress innersprings of substantially any dimensions.

Abstract: The invention concerns a process for folding a flexible piece, in particular to upholster an object such as chair fitting with a flexible cover. The upholstering or covering process comprises cutting out a flexible piece (25) to a shape corresponding to that of the object plus a border on its contour, providing the edge of this border with a tensioning thread sliding within a passage preserved by auxiliary threads, covering the object with the piece so that the border provided with the tensioning thread project beyond the object contour, folding back the border and applying tractions in opposite directions on the two ends (5a, 5b) of the tensioning thread to tighten and to fold this border, lastly, after the tractions have been applied, locking the ends of the tensioning thread either by tieing them together or by stapling them to the back of the object or by crushing a punched-out clip (31) on the back of the object.

Abstract: Apparatus for automatically securing borderwires on mattress innersprings, comprising support members for receiving borderwires and a mattress innerspring in stacked, properly oriented relation to one another. A drive mechanism is provided for automatically sequentially advancing the borderwires and the mattress innerspring along the support members to a clip wrapping station where a plurality of clips are simultaneously wrapped on the borderwires and the coils of the mattress innerspring. Control elements are provided for sensing when clips are to be wrapped, and when a predetermined number of clips have been wrapped on each side and each end of borderwires and the mattress innerspring.

Abstract: A process for molding upholstered chair cushions comprising placing a sheet of upholstery fabric between two dies, one having sculptured effects thereon, the dies being movable toward each other to form a cavity between them. A cushion assembly having a thickness (with the upholstery) greater than the distances between the dies in the cavity is placed in the cavity after having been coated on at least one side adjacent the upholstery with an air permeable adhesive. The dies are urged together to compress the cushion in the cavity to force the fabric and the cushion to conform to the shape of the first die. Hot vapors are injected into the cavity to shape the cushion and the fabric generally to the sculpted configuration of the sculpted die.

Abstract: Anchor track for attachment thereto of a seat cover through intermediation of C-rings, with the anchor track having serrations for locking C-rings thereto, and being secured to bottoms of front and side channels of automotive front seat frame.

Abstract: The padded frame of a seat being upholstered rests on a support placing the back of the seat in vertical alignment under a carriage mounted on guides establishing a vertical freedom of movement of the carriage. The carriage has a cluster of resilient cantilever arms extending downward, each of the arms having a follower at the lower end adapted to move along the contour of the seat back. The cover for the seat back is slipped inside-out over the cluster of arms, and relative movement of the carriage toward the seat installs the cover outside-out. Other resilient arms in the cluster are preferably mounted on the frame of the machine, with relative movement provided by moving the seat unit with respect to the frame.