Abstract: A furniture cushion comprises a matrix of interconnected pocketed springs, each spring of which is contained within a pocket of fabric, and a fiber pad overlying an upper surface of the matrix of pocketed springs, the fiber pad having a first layer in contact with the upper surface of the matrix of pocketed springs and a second layer in contact with the first layer, the first layer having a first density and said second layer having a second density, the first density being greater than the second density. At least one edge guard may be secured to the matrix of pocketed springs.

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 furniture cushion comprises a matrix of interconnected pocketed springs, each spring of which is contained within a pocket of fabric, and a fiber pad overlying an upper surface of the matrix of pocketed springs, the fiber pad having a first layer in contact with the upper surface of the matrix of pocketed springs and a second layer in contact with the first layer, the first layer having a first density and said second layer having a second density, the first density being greater than the second density. At least one edge guard may be secured to the matrix of pocketed springs.

Abstract: The subject invention relates to a warp-knit fabric and methods of constructing the fabric. The fabric includes a plurality of walewise stitch-loop chains and a weftwise elastomeric thread running in successive courses and held in place by the stitch-loop chains. The fabric may include border segments that have filling yarn disposed weftwise across the stitch-loop chains.

Abstract: A furniture cushion comprises a matrix of interconnected pocketed springs, each spring of which is contained within a pocket of fabric, and a fiber pad overlying an upper surface of the matrix of pocketed springs, the fiber pad having a first layer in contact with the upper surface of the matrix of pocketed springs and a second layer in contact with the first layer, the first layer having a first density and said second layer having a second density, the first density being greater than the second density.

Abstract: This invention is directed to an apparatus for attaching webbing to a furniture frame. The apparatus includes a frame, a mounting assembly, and a webbing attachment assembly. The mounting assembly includes a clamping mechanism and a rack. The clamping mechanism is coupled to a lower portion of the frame while the rack is coupled to an intermediate portion of the frame. The clamping mechanism and rack are adapted to receive at least one furniture frame and hold the furniture frame in place. The webbing attachment assembly is coupled to the frame and is adapted to position the webbing relative to the at least one furniture frame to enable the webbing to be attached to the furniture frame.

Abstract: The subject invention relates to a warp-knit fabric and methods of constructing the fabric. The fabric includes a plurality of walewise stitch-loop chains and a weftwise elastomeric thread running in successive courses and held in place by the stitch-loop chains. The fabric may include border segments that have filling yarn disposed weftwise across the stitch-loop chains.

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: This invention is directed to a method and apparatus for attaching webbing to a furniture frame. The apparatus includes a frame, a mounting assembly, and a webbing attachment assembly. The mounting assembly includes a clamping mechanism and a rack. The clamping mechanism is coupled to a lower portion of the frame while the rack is coupled to an intermediate portion of the frame. The clamping mechanism and rack are adapted to receive at least one furniture frame and hold the furniture frame in place. The webbing attachment assembly is coupled to the frame and is adapted to position the webbing relative to the at least one furniture frame to enable the webbing to be attached to the furniture frame.

Abstract: A high resiliency elastomeric seating composite adapted for use on a chair is provided. The seating composite includes an adhesive layer positioned between a film layer and an elastomeric net material. The film layer may be formed of urethane, vinyl or a combination thereof and is cast onto a sheet of release paper. The release paper is removed from the film layer and the adhesive layer is positioned between the film layer and elastomeric net material. The film layer, adhesive layer and net material are then flame laminated to form the seating composite. The adhesive layer is formed of a urethane foam material and the elastomeric net material may be formed of a polyester elastomeric material that is woven or biaxially-oriented extruded. In an alternative embodiment, the film layer is cast directly on the net material without the use of the adhesive layer.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A seating suspension assembly provides efficiency in the manufacture of upholstered furniture such as chairs, sofas or the like. The preferred form of the invention comprises a pair of flexible, durable fabric straps having coil springs fixedly positioned therebetween. The fabric can be attached to a rigid wooden chair seat frame and the suspension assembly stapled or tacked thereto. The coil springs are thus suspended between the front and back of the frame. Upon upholstering, the suspension assembly provides a comfortable, crowned seat for the user. A method of forming the seating suspension assembly is also disclosed.

Abstract: A seating suspension assembly provides efficiency in the manufacture of upholstered furniture such as chairs, sofas or the like. The preferred form of the invention comprises a pair of flexible, durable fabric straps having coil springs fixedly positioned therebetween. The fabric can be attached to a rigid wooden chair seat frame and the suspension assembly stapled or tacked thereto. The coil springs are thus suspended between the front and back of the frame. Upon upholstering, the suspension assembly provides a comfortable, crowned seat for the user. A method of forming the seating suspension assembly is also disclosed.

Abstract: A method of forming cushions by needle punching is demonstrated in which superior structural integrity is achieved without adhesives or other external fasteners. The process is economical and utilizes polyurethane foam which is mechanically bound by needle punching to various polymeric fibers. In an alternate embodiment of the process, the needle punching causes the fibers to penetrate the foam block at an angle to the vertical for greater mechanical bonding between the fiber layer and the foam block. The cushion so formed by the various processes can be covered or upholstered as needed for furniture seating and other purposes.

Abstract: A resilient fiber mass and method of forming the same is provided whereby a conventional batting is sprayed with a polyurethane prepolymer and is then in one embodiment rolled into a tight cylindrical shape for subsequent molding. A steam catalyst is introduced into a mold having a specific shape which causes the prepolymer to foam and polymerize. The foaming action separates the fibers at the intersections to provide resiliency to the fiber mass. The molded mass is then removed and can, for example, be attached to a chair seat and covered with decorative fabric as is standard in furniture manufacturing. The chair cushion so formed is highly resilient and durable.

Abstract: A seating suspension assembly provides efficiency in the manufacture of upholstered furniture such as chairs, sofas or the like. The preferred form of the invention comprises a pair of flexible, durable fabric straps having coil springs fixedly positioned therebetween. The fabric can be attached to a rigid wooden chair seat frame and the suspension assembly stapled or tacked thereto. The coil springs are thus suspended between the front and back of the frame. Upon upholstering, the suspension assembly provides a comfortable, crowned seat for the user.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A furniture seat spring assembly is presented which allows simplicity and economical seating for chairs, sofas or the like. The spring assembly comprises a U-shaped base having an eccentrically positioned coil spring which is covered with an elastic webbing. The eccentric position of the spring allows the user's weight to depress the webbing without "feeling" the coil spring which is positioned near the seat frame front rail. Multiple assemblies are positioned at selected intervals within conventional seat frames, depending on the particular frame size used.