Abstract: A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.

Abstract: A sewing machine comprises a crank shaft, a first drive shaft, a second drive shaft, a needle assembly, a presser foot, and an upper walking foot. A first crank arm assembly is connected to the crank shaft to the first drive shaft. A first linkage assembly is connected to the first drive shaft to the needle assembly. A second crank arm assembly is connected to the first drive shaft to the second drive shaft. A second linkage assembly is connected to the second drive shaft to the presser foot and the upper walking foot. The second linkage assembly is configured to cause out-of-phase reciprocatory movement of the presser foot and the upper walking foot. The second crank arm assembly has a variable length that is selectably adjustable by an operator to yield at least first and second different stepping heights of the upper walking foot.

Abstract: A metal-to-the-floor linkage mechanism provides backrest recline and ottoman extension for a seating unit. The linkage mechanism has a base and a pair of seat mounting plates that are used to attach a seat to the mechanism. The linkage mechanism comprises a first and a second plurality of links that are each pivotally coupled between the base and a corresponding one of the pair of seat mounting plates. The first and second plurality of links moveably interconnect the base and the seat mounting plates to control movement of the seating unit between closed, TV, reclined and fully-reclined positions. In the fully-reclined position, the seat mounting plates are moved to a position by the first plurality of links and the second plurality of links to place the seat of the seating unit at an angle relative to horizontal of between eighteen and twenty-six degrees.

Abstract: A bedding or furniture product comprises a foldable leg assembly movable between a folded position for storage or shipping the product and a locked position for supporting the product in use. The foldable leg assembly comprises a threaded connector adapted to be securable to a frame of the product and a linkage member pivotally coupled to the threaded connector to form a pivot joint therebetween. The leg assembly further comprises a leg member coaxially coupled to the linkage member and slideable therealong. The leg member has a threaded inner surface adjacent to an upper end configured to be threadably coupled to the threaded connector.

Abstract: A simplified, compact, recliner mechanism which can be adapted to essentially any type of seating unit is disclosed. The seat-drop and the over-center linkages, as well as the seat-drop movement, may be eliminated utilizing a simplified recliner linkage and a linear actuator to control movement of the recliner mechanism.

Abstract: A bedding or furniture product comprises a foldable leg assembly movable between a folded position for storage or shipping the product and a locked position for supporting the product in use. The foldable leg assembly comprises a threaded connector adapted to be securable to a frame of the product and a linkage member pivotally coupled to the threaded connector to form a pivot joint therebetween. The leg assembly further comprises a leg member coaxially coupled to the linkage member and slideable therealong. The leg member has a threaded inner surface adjacent to an upper end configured to be threadably coupled to the threaded connector.

Abstract: A furniture system includes a base, a first linkage and a second linkage. The base is configured to be disposed on a flat surface and to be connected to an article of furniture. The first linkage is connected to the base and configured to be connected to the article of furniture. The first linkage is configured to be actuated to cause the article of furniture to translate relative to the base. The second linkage is connected to the first linkage. The second linkage is biased into a locked state in which the second linkage prevents movement of the first linkage. The second linkage is configured to be actuated by an applied force into an unlocked state in which the second linkage allows movement of the first linkage (and the article of furniture to which the first linkage is configured to be connected).

Abstract: A mechanism is provided for a seating unit that moves the seating unit between closed, TV, and fully reclined positions. The mechanism allows independent movement of a seat frame, relative to the chair arms and chair back to which the mechanism is mounted. The mechanism thus allows the seat depth of the chair to be adjusted relative to the chair back to accommodate the individual characteristics of the chair occupant.

Abstract: Pultruded frames for an adjustable bed are described herein. The pultruded frames may include various components such as connection/joining and reinforcing structures. The various components and frame parts may be combined in multiple configurations to form light weight and strong adjustable bed frames.

Abstract: A metal-to-the-floor linkage mechanism provides backrest recline and ottoman extension for a seating unit. The linkage mechanism has a base and a pair of seat mounting plates that are used to attach a seat to the mechanism. The linkage mechanism comprises a first and a second plurality of links that are each pivotally coupled between the base and a corresponding one of the pair of seat mounting plates. The first and second plurality of links moveably interconnect the base and the seat mounting plates to control movement of the seating unit between closed, TV, reclined and fully-reclined positions. In the fully-reclined position, the seat mounting plates are moved to a position by the first plurality of links and the second plurality of links to place the seat of the seating unit at an angle relative to horizontal of between eighteen and twenty-six degrees.

Abstract: A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies of fabric. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least cushion pad is positioned in each outer pocket. The cushion pad may be individually pocketed. An upper end of each transverse seam may be below an upper surface of the string to partially separate adjacent outer pockets within a string.

Abstract: A flexible foam composition includes a flexible foam body having a surface, which flexible foam is polyurethane and/or latex flexible foam, and an expandable graphite layer on the surface or within the foam surface adjacent to the surface. The flexible foam composition with the expandable graphite layer imparts improved flame retardant properties to the composition.

Abstract: A comfort layer for a bedding or seating product has slow-acting pockets characterized by the individual mini coil springs of the comfort layer being pocketed with either semi-impermeable or impermeable fabric. Each weld seam joining opposed plies of fabric around each of the coil springs of the comfort layer may be segmented, allowing air to flow between the segments, thereby increasing the luxury “feel” of the comfort layer. The method of making the comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.

Abstract: An apparatus for upholstering a truss allows an operator to staple a fabric web to the truss, rotate the truss, further staple the semi-finished truss and cut the fabric web. The truss is fully upholstered after the end surfaces of the truss are wrapped up in fabric and the fabric stapled in place. The apparatus may accommodate different size trusses. A web of fabric is pulled around at least one roller in the apparatus by rotation of two vise mechanisms on opposite sides of the truss.

Abstract: A motorized positioning apparatus for a seating unit includes a motor assembly that is configured to move a linkage assembly though a series of positions that arrange the seating unit in a closed position, open position, or extended position. The motor assembly attaches directly to a footrest drive link by way of a mounting tube. In addition, the motor assembly may attach either to a base rail of the seating unit or to a rear pivot link by way of a rear mounting tube.

Abstract: Apparatuses, methods, and computer program products for quilting webs. A quilting machine includes a cutting edge, a looper from which thread is provided to form stitches, and an adjuster assembly. The adjuster assembly extends an adjuster toward the thread between the looper and the retainer. When the adjuster is moved, a predetermined amount of thread is pulled away from the looper by the adjuster to provide a controlled length of thread between the looper and the cutting edge. The looper assembly may also include an air nozzle that urges the thread away from the adjuster after the thread has been cut. The thread passes through a thread tension monitor that monitors tension in the thread. The tension monitor includes a lift arm that selectively disables the tension monitor so that a loss of tension in the sewing head does not shut down the quilting machine.

Abstract: Combinations of open cell flexible foams with polyurethane gel particles, and methods of making the combinations are described using a variety of procedures. The open cell flexible foam may partially or wholly comprise polyurethane foam and latex foam.

Abstract: A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.

Abstract: Methods and combinations of mattress support surfaces comprising one or more flexible polyurethane foam layers containing highly thermally-conductive solids, such as diamond or silicon carbide, and said layer combination is capable of transferring heat from a warm surface, such as a person sleeping on a bed, to a cooler region at a faster rate throughout the mattress than the thermal dissipation rate obtained from flexible polyurethane foam without highly thermally-conductive solids.

Abstract: A linkage mechanism provides motion capabilities for various chair types. For example, a linkage mechanism includes a combination of links that facilitate ottoman extension/closing and backrest recline/incline. In addition a linkage mechanism includes a compact design that is usable with hi-leg style chairs having a relatively low seat height.