Abstract: Provided is a linkage mechanism for a recliner that includes a seat-mounting plate, a base plate vertically supported by high-legs, a footrest assembly adapted to extend ottoman(s) forward when the recliner is adjusted from a closed to an extended position, and a seat-adjustment assembly. The seat-adjustment assembly includes an ottoman drive link that has a front end pivotably coupled to the footrest assembly and a rear end pivotably coupled to a mid section of a connecting link. The connecting link further includes a front end rotatably coupled to a forward portion of the base plate and a rear end rotatably coupled to a lower end of a rear pivot link. The rear pivot link further includes an upper end that is pivotably coupled to a rearward portion of the seat-mounting plate. The combined operation of three links above locates the seat-adjustment assembly above the base plate's lower edge during adjustment.

Abstract: A screening for separating a protected area from a more accessible area includes a plurality of vertical supports with panels retained between the supports. The upper or lower ends of the panel are retained on pivot pins while the end of the panel opposite the pivot pins is removably locked to the support. The locking structure includes a latch that can be released from a position outside the enclosure and a lock that is lockable and unlockable from inside the enclosure. When the lock is actuated, the latch cannot be unlatched until the lock is subsequently unlocked.

Abstract: An automated flanging machine is provided. More specifically, a machine for automatically sewing a flange onto a work panel having a consistent corner radius and a straight edge is provided. The machine has a table adapted to support a work panel, a sewing head mounted directly adjacent to the table for performing a sewing operation on the work panel, a turning arm mounted adjacent to the table, and a rear conveyor for selectively moving the work panel on the table. The table may include a corner pivot mechanism for stabilizing the panel while the turning arm turns the panel 90 degree relative to an initial position, and for maintaining a consistent corner radius for sewing. The machine may also include a rear material guide and encoding arm for measuring the progression of the work panel as it is sewn along a side by the sewing head.

Abstract: A seating unit that includes a linkage mechanism adapted to adjust between closed, extended, and reclined positions is provided. The linkage mechanism includes a seat-mounting plate mounted to a footrest assembly, a back-mounting link and a rear bellcrank both rotatably coupled to the seat-mounting plate, an activator bar that controls a footrest drive link, and a linear actuator for carrying out automated adjustment of the linkage assembly. In operation, a stroke in a first phase of the linear actuator generates a torque on the activator bar. The footrest drive link converts the torque into a laterally-directed force that pushes the footrest assembly into the extended position. A stroke in the second phase acts to push the activator bar forward and translate the seat-mounting plate forward at a consistent inclination angle. The forward translation causes the rear bellcrank to rotate, thereby biasing the back-mounting link rearward into the reclined position.

Abstract: An apparatus is provided which makes a border wire having a rectangular cross-section. The apparatus is adapted to receive a roll of wire having a circular cross-section, straighten the wire and change the cross-section of the wire to rectangular. The reconfigured wire is then accumulated, passed through another straightener, cut to size and then bent into a rectangular configuration. Opposed ends of the piece of wire having a rectangular cross-section are welded together to complete the border wire. The apparatus has an ejector which removes the completed border wire from the apparatus.

Abstract: An automated powder-coating system and method is provided. A series of conveyor belts are arranged end to end to transition one or more work pieces between the conveyor belts. Sensors are used to determine the current location of a work piece with respect to the series of conveyor belts. An induction heating coil for preheating work pieces and a powder-coating apparatus for powder coating work pieces are located adjacent to the conveyor belts. A control unit independently starts and stops the individual conveyor belts based on the current location of the work piece. A cooling area may also be included in the powder-coating system. The powder-coating system and method may be used to powder coat varying lengths of work pieces.

Abstract: Various methods for installing an article of fabric to a frame to provide an improved seating product, which can be integrated in essentially any type of seating unit, are provided. These methods include a pre-forming operation that deforms the frame prior to securing the fabric article thereto, and a securing operation that leverages post-mold shrinkage properties of the frame to secure the fabric article thereto. The pre-forming operation generates tension in the fabric article, which spans the frame, by initially deforming the frame utilizing compression mechanisms of an assembly fixture and subsequently loading the fabric article to the frame in a loose condition. Upon releasing the compression mechanisms, the fabric article assumes a taut condition that expresses the tension. The securing operation involves inserting a segment of the fabric article into a groove in the frame and allowing the groove to naturally clamp the segment during post-mold shrinkage.

Abstract: A mechanism for securing a mattress on an automated bed is provided. More particularly, the invention relates to a mattress-retention mechanism for preventing a mattress from moving towards the foot end of a bed during articulation. The mattress-retention mechanism includes a mattress-support structure adapted to support a corner of a mattress, with a portion of the mattress-support structure having a curved interior surface. The mattress-support mechanism also includes a foundation attachment surface for removably attaching the mattress-retention mechanism to the top of a mattress foundation, where the foundation attachment surface is perpendicular to the curved interior surface. The mechanism may include a bedding aperture on the side of the mattress-support structure to accommodate bedding inserted through the bedding aperture. Further, the mechanism may include a side attachment surface for removably attaching the mattress-retention mechanism to a vertical side of the mattress foundation.

Abstract: A drop-in grid base for coil units is provided. A plurality of extruded plastic tubes, plastic-covered wire profiles, and cross wires are arranged in substantially the same plane to form a grid foundation. The cross wires intersect the extruded plastic tubes and wire profiles. Base wires having a series of shallow, v-shaped notches are interwoven in substantially the same plane as the grid foundation. The ends of the base wires are looped for attachment inside the seating cavity of a framed furniture product. A coil unit may be attached directly to the drop-in grid base. Alternatively, the drop-in grid base may be separately installed into a seating cavity frame, for later installation of a coil unit on top of the drop-in grid base.

Abstract: A mounting device for mounting an object on a support includes a base configured to be coupled to the support, and a slide arm coupled to the base and movable between a retracted position and a plurality of extended positions. The slide arm is movable from any of the plurality of extended positions to the retracted position by sliding the slide arm relative to the base without any other manipulation of the mounting device by the user. The slide arm automatically locks relative to the base when the slide arm is moved to the retracted position.

Abstract: A bedding or seating product comprising a spring core including at least one border wire and a plurality of coil springs. Each of the border wires is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire. Each of the coil springs may be made of a single piece of wire having a central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns. The coil springs may be arranged in side-by-side rows and columns and be connected with each other at the upper and lower end turns by helical lacing wires.

Abstract: Inductive coupling modules for providing power to secondary devices placed in proximity thereto on a surface are described. The modules include above-surface, flush, recessed, and sub-surface mounting configurations. The modules further include dual housing, single housing, low-profile, and adjustable configurations. Inductively coupled power distribution circuits are also disclosed. The circuits comprise a plurality of segments that are inductively couple together to eliminate wired connections between segments. Each segment may be attached to a section of a modular furniture component to allow ease and safety in rearranging the modular furniture and ease in reconnecting the circuit.

Abstract: Subject matter described herein includes a seat assembly (e.g., chair, bench, sofa, vehicle seat, etc.) having a seat and a back rest that adjust together to facilitate reclining. The seat assembly includes a base coupled to a back-rest frame. The base remains substantially fixed relative to synchronized adjustment of the seat and the back rest, and the back-rest frame includes a pivot on which the back rest rotates to adjust a back-rest recline position. The assembly also includes the seat hingedly coupled to the back rest and a fore-and-aft adjuster that couples the seat to the base. A movement restrictor attaches to the seat and the base and biases the seat in a rearward orientation. The assembly further includes a pivot receiver coupled to the back rest, the pivot receiver providing a path along which the pivot travels when the seat moves forward and rearward.

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). Cushioning material is located between adjacent rows of pocketed springs to reduce noise.

Abstract: A furniture product includes a folding mechanism that folds into a seat frame. The folding mechanism includes a rear section, a middle section, and a front section, with the rear and middle sections being received in a cavity in the back of the seat frame when the product is in a stowed, seating position. Upon receiving a user input, a position motor deploys the folding mechanism into a sleeping position. Upon achieving the sleeping position, an inflation switch is engaged. An air pump disposed in or near the furniture product is activated in response to engagement of the inflation switch. To return the product to a stowed, seating position, a user input causes the air pump to deflate the mattress and the position motor to fold the folding mechanism into the seat frame.

Abstract: The present invention is directed to a furniture item having user-support frames that are convertible between a seat configuration and a bed configuration. In one embodiment, user-support frames include a head-support frame anchored by a link assembly to a furniture-item base and a back-support frame pivotably coupled to the head-support frame. The link assembly facilitates both pivoting and lateral shifting of the head-support frame relative to the furniture-item base. In the bed configuration, a cam and cam follower are disposed under the user-support frames, such that when the user-support frames laterally shift, the cam contacts the cam follower, thereby upwardly moving a junction at which user-support frames are hinged to one another.

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). Fibrous material is located between adjacent rows of pocketed springs and upper and lower sheets are secured to at least some of the strings of springs to reduce noise.

Abstract: A self-forming mattress cover including a mattress gusset with a drawstring is provided. The gusset includes a sleeve attached to the gusset along a fold location. A drawstring is disposed within the sleeve. Ends of the drawstring are pulled into tension, thereby reducing the perimeter of the gusset at the fold location and drawing the gusset inward toward the center of the mattress. The gusset is formed to corner positions of the mattress by stretching and/or bunching of gusset material as tension is applied. The ends of the drawstring are secured to retain the tension state. A cushioned quilt top is attached to a free edge of the gusset. The self-forming mattress cover conforms to corner positions of a mattress without the need for mitering, ruffling, pleating, or sewing seams at the corner positions. The self-forming mattress cover also ensures proper alignment of the cushioned quilt with the mattress body.

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: A linkage that provides a fully flat reclined position is described. The linkage includes a full-flat lift link pivotally coupled to a seat support link. A backrest support link couples to the lift link through an oblong aperture to provide additional range of motion. The lift link includes a laterally extending flange, the perimeter of which acts as a cam surface for a cam pin that obstructs reclining of the backrest support link when the rocker-recliner is in an upright position. When fully reclined, the linkage configures a footrest, seat portion, and backrest portion in a generally equal plane to provide a fully flat seating surface.