Abstract: A nonwoven fiber product comprises a coarse fiber web comprising a plurality of coarse fibers and substantially free of any fine fibers, and a fine fiber web comprising a plurality of the fine fibers and substantially free of any of the coarse fibers, wherein the coarse fiber web is positioned adjacent to the fine fiber web. A method of making a nonwoven fiber product comprises blending a plurality of coarse fibers into a coarse fiber blend that is substantially free of fine fibers, blending a plurality of fine fibers into a fine fiber blend that is substantially free of coarse fibers, forming the coarse fiber blend into a coarse fiber web, and forming the fine fiber blend into a fine fiber web, wherein the fine fiber web is formed adjacent to the coarse fiber web.

Abstract: Plastic compositions formed from post consumer plastic waste and methods for making such plastic compositions are provided. In one aspect, a method for forming a plastic product includes providing a first composition comprising at least 30 weight percent of a first plastic and at least 30 weight percent paper products. The method also includes providing a second composition comprising at least 90 weight percent of a second plastic. The first and second compositions are each shredded and commingled to form a shredded mixture. The shredded mixture is heated to form a shapeable plastic, which is molded and cooled to form the plastic product.

Abstract: A quilting machine has at least one needle and looper set for forming chain-stitched patterns on a thick multilayered material such as a mattress ticking, preferably a panel of the continuous web clamped stationary on a frame. The stitch forming elements are mounted on separate heads that move independently transversely relative to the panel on a bridge that moves longitudinally relative to the panel. The bridge is longitudinally moved by a servo and the heads are transversely moved on the bridge by separate linear servos. The needle and looper are each driven by a linear servo having an armature to which the element is directly fixed to reciprocate without intervening mechanical linkage assemblies. A controller drives the servos to chain-stitch patterns, differentially move the heads transversely to account for transverse needle deflection and to phase the needle and looper to compensate for longitudinal needle deflection.

Abstract: This invention is directed to a mattress assembly for use in a sofa sleeper. The mattress assembly has an outer shell and an inner support received within the outer shell. The shell includes a lower panel, a sidewall, and a cover that fit together to form a cavity to receive the inner support. The inner support includes an air bladder and an innerspring portion. The air bladder has a valve that is adapted to allow air into and out of the bladder. The air bladder is deflated when the mattress is stored to provide a compact configuration.

Abstract: This invention is related to a knock down frame attachment system. The knock down frame attachment system includes a seating portion, a pair of side panels and a plurality of sets of mounting brackets. A set includes both a left and a right mounting bracket. A set of brackets are coupled to each side of the seating portion and to both side panels. Thus, two sets of brackets are required to attach a side panel to the seating portion.

Abstract: A two-piece motion-transmitting cable assembly includes first and second cables, each having a core wire surrounded by a conduit; a male housing connected to the first cable and having a ridged length adjustment section; a spring retainer slideably interconnected with the exterior of the male housing and having a female retaining clip at a first end; a female housing connected to the second cable and having a male retaining clip engaging with the female retaining clip when the male and female housings are mated; an adjustment clip engaging with the ridged length adjustment section to lock the male housing in a position relative to the female housing; and a spring contained between the exterior of the male housing and the interior of the spring retainer and interacting with the spring retainer, in conjunction with the retainer clip, to bias the first cable in a direction toward the second cable.

Abstract: A fusible quilt batt. The fusible batt includes a non-woven fibrous web and a heat sealable and releasable adhesive. The adhesive is coated on the outer surface of the web and insinuates between the fibers of the web internally. The adhesive thus binds the fibers of the web and provides a tackiness sufficient to allow the web to be applied to a backing material at an elevated temperature and removed from the backing at room temperature or an elevated temperature. After removal of the web from the backing material it may be reapplied to a backing material at an elevated temperature. The attachment, removal and reattachment process is repeatable.

Abstract: A pole connector assembly for connecting adjacent pole sections in order to construct a pole. In some embodiments, these pole connector assemblies have two inserts connected together by a fastener. Each of the two inserts can be received within an open end of a respective pole section. The fastener can be received within an aperture in each of the inserts in order to connect the pole sections together. In some embodiments, each insert can have at least one projection that extends into the pole section within which the insert is received. The fastener can limit the at least one projection from being inwardly deflected in order to secure the insert within the corresponding pole section. In other embodiments, the fastener can have at least one deformable portion to allow the fastener to secure the insert within the corresponding pole section.

Abstract: A synchrotilt chair mechanism and a chair are provided. The synchrotilt chair mechanism is for use on a chair that has a base assembly with an extending pedestal, a seat and a back. The mechanism includes a chassis that is coupled to the pedestal and a seat plate that is coupled to the chassis and to the chair seat. The seat plate can slide relative to the chassis. The mechanism further includes a back support bar that is coupled on one end to the chassis. The support bar extends upwardly from the chassis. A pair of arm supports are further included that can be coupled to the chair. Each arm support extends upwardly adjacent one side of the chair seat. The mechanism further includes a back bracket having a pair of ends that extend adjacent a side of the chair. Each end is pivotally coupled to the adjacent arm support. The back bracket further includes a guide plate that mounts to the chair back and that has at least one guide slot.

Abstract: A bed frame that can be assembled without the use of additional tools. The bed frame generally comprises a pair of spaced side rails, retainer brackets secured to each side rail, and cross support members extending between the side rails. Each retainer bracket has a base section for supporting one of the cross support members and an aperture extending through the base section. The apertures are aligned with threaded bores in the cross support members so that threaded portions of respective leg assemblies may be inserted through the apertures and used to secure the cross support members to the corresponding retainer brackets.

Abstract: A plurality of concrete reinforcing grid modules each comprising a plurality of spaced longitudinal wires and a plurality of spaced transverse wires may be nestably stacked together and sold as a package. The transverse wires are secured to the longitudinal wires at intersections. Each grid module may be secured to other like grid modules without the use of tools or additional material because least some of the grid module wires have tail portions at the ends thereof which interlock with the wires of other grid modules.

Abstract: A recycled energy absorptive/moisture resistive underlayment includes a recycled energy absorbing layer comprised of either a nonwoven fiber batt formed from shoddy fibers or a foam pad formed from bonded foam. To protect the recycled energy absorbing layer from moisture, a moisture barrier is laminated on either one or preferably both side surfaces of the recycled energy absorbing layer. The moisture barrier laminated on a lower side surface of the recycled energy absorbing layer has a projecting flap which projects from first and second edge surfaces of the recycled energy absorbing layer to which the moisture barrier is laminated to the lower side surface thereof. The projecting flap enhances protection of the recycled energy absorbing layer from moisture by preventing moisture from migrating through seams and/or other exposed portions of the recycled energy absorbing layer.

Abstract: A product storage and display structure includes uprights, at least one shelf, and at least one shelf ledge. The shelf ledge includes first and second opposite ends, each end adapted to be removably coupled to an upright of the product storage and display structure. A barrier portion extends upwardly from the base portion, wherein when the base portion is coupled to the uprights, the barrier portion extends to a location proximate and at a higher elevation than the shelf of the product storage and display structure.

Abstract: Some embodiments of the present invention employ a modular room including a plurality of modular room components (e.g., anchor assemblies, upright assemblies, etc.). These anchor assemblies and upright assemblies can take different forms permitting assembly of a modular room or modular structure in different manners, and in some cases provide for interchangeable interior and exterior wall panels and components. In some embodiments, a bracket assembly is coupled to an substantially vertical elongated upright for improved strength and stability. Preferably, the anchor assembly has a base plate with at least one edge at an angle with respect to the rest of the base plate for additional strength. If desired, the vertical position of the upright with respect to the base plate can be adjusted. In some embodiments, one or more overhead trusses are used to stabilize the walls of a modular room.

Abstract: A block attacher for attaching blocks to slats as stringers for pallets includes a slat dispenser disposed to dispense individual slats to a slat driver, the slat driver being selectively positionable. A first block dispenser dispenses a block to an assembly station where a position fixture is disposed to operatively cooperate with the slat driver and the block dispenser to position the dispensed block abutting the individual slat when the slat driver is in a first selected position. At least one other position fixture is disposed to operatively cooperate with the slat driver to position a second dispensed block abutting the individual slat when the slat driver is in a second selected position. The subsequent blocks may be dispensed by the same block dispenser as the first block, or by different dispensers.

Abstract: A simplified, low-cost actuator used in conjunction with a lumbar support device designed to significantly decrease manufacturing costs and assembly time. The present invention produces similar movement as the more expensive actuators but does so with a considerably smaller number of parts. The actuator consists merely of four pieces—a handle, a spring, a plunger, and a mounting bracket. The symmetry of design of this actuator allows it to be installed more easily in any orientation and on either side of the seat. Furthermore, the actuator may be adapted for use with a tension cable or a drive rod. The simplicity, low-cost, and ease of use associated with this actuator makes it an attractive alternative to other actuators disclosed in the prior art. Finally, this actuator allows adjustable lumbar support to be offered in a cost effective manner in lower tier seating.

Abstract: A horizontal adjustment mechanism for use with a chair having a base, a seat supported on the base and a seat back. The mechanism includes a first plate that is to be coupled to the base and a second plate that is coupled to the seat. The second plate includes a mating portion. The second plate is slidably coupled to the first plate such that the second plate can move relative to the first plate. The mechanism also includes a lever mechanism. The lever mechanism includes a mating portion that selectively disengages from the mating portion of the second plate to allow the second plate to move relative to the first plate.

Abstract: Disclosed herein is a bedding or seating product having a spring core comprising coil springs having unknotted end turns made from high tensile strength wire. In each embodiment, the end turns of the coil springs are generally U-shaped having one leg longer than the other, the legs being joined by an arcuate connector. The springs are oriented in the spring core such that a long leg of one end turn abuts a short leg of the adjacent end turn prior to be wrapped in helical lacing wire. The high tensile wire enables the coil springs to be manufactured using less wire than heretofore possible.

Abstract: The present invention relates to a method for forming a fire combustion modified batt. The method comprises the step of forming a blend of nonwoven and oxidized polyacrylonitrile fibers into a web. The oxidized polyacrylonitrile fibers are fire resistant and when blended with nonwoven fibers are relatively easily processed into a batt. A second blend of nonwoven fibers can be formed into a web and layered with the oxidized polyacrylonitrile fiber web to form the batt. The fibers are bonded together with heat, resin or other bonding material and are compressed and cooled. The fire combustion modified batt is useful as fire barriers and fillers in bedding, upholstery and vehicle and aircraft seats, as insulators for apparel, appliances, walls and ducting, as barriers to separate control systems from a heat source, and as components in fire safety gear such as race driver suits and oven and welding mitts.