Abstract: A seat assembly having a seat base. A seat pan is operably connected to the seat base. A rod extends across the seat base into elongated slots in the seat pan. An engagement member is operable between a first position out of contact with the rod and a second position in contact with the rod. A motor includes a drive shaft operably connected with the rod and adapted to rotate the rod. Rotation of the drive shaft when the engagement member is in the first position causes lateral displacement of the seat pan. Rotation of the drive shaft when the engagement member is in the second position causes rotation of the rod and the seat pan.

Abstract: A self-adjusting mattress includes a support member, top and bottom foam layers, a movement mechanism and balancing bars. The support member includes a frame of longitudinal and cross bars and mesh panels between the bars. The support member has a middle section that is pivotally connected to upper and lower sections. The upper, middle and lower sections are coplanar in the flat configuration of the mattress. The movement mechanism includes multiple electric motors that move the mattress into an inclined configuration by rotating the upper and lower sections relative to the middle section. The bottom foam layer is molded around the support member. The molded foam flows above, below and through the holes in the mesh panels. The top foam layer is then glued or molded to the top of the bottom foam layer. The balancing bars extend less than half way under the upper section of the support member.

Abstract: A method for fabricating pet beds that are uniform in shape that is cost effective and rapidly completed. A plug is wrapped in several layers of foam or padding. Each layer of foam is coupled to each other, however the plug is not coupled to any of the foam layers itself. After the foam has been properly placed, the plug is removed and a spring set that is substantially shaped like the plug is inserted into its place. The foam and spring set are then enveloped within a mattress cover. The pet bed may be fabricated in a plurality of shapes using the same process including oval or elliptical, circular, triangle or wedge, and rectangular. Each shape may also be fabricated using the same process in a “flat” or “high back” configuration.

Abstract: An object of the invention is to provide molded urethane foam pads and vehicle seats that can contribute to the reduction of environmental load and have appropriate impact resilience and hardness and excellent durability with good balance, and also have high comfort.

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: By providing a unique product enhancing step which enables any desired section, portion, or element of a product being produced to be treated in a manner to provide desired enhanced physical, structural, and/or aesthetics characteristics, a new, fully integrated enhanced foam manufacturing system is attained which is capable of producing virtually any desired foam product, with each product incorporating any desired area or zone being formed with a particular physical, structural, and/or aesthetic property, characteristic, or enhancement. In addition, in accordance with the teaching of the present invention, any desired cross-sectional shape or configuration is capable of being manufactured in fully automated, high volume, rapid production conditions, with virtual ease and simplicity, with a specific physical, structural, or aesthetic property incorporated therein.

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). Fill material, such as pieces, strands or elements of foam or fiber is located inside at least some of the pocketed springs to reduce noise.

Abstract: A panel member assembly forming a pocket, and a method for fabricating the panel member assembly is provided. The panel member assembly including a panel including a non-linear slot which may be a generally U-shaped slot, an insert which is inserted into the slot to form the pocket, and a retainer attachable to the panel to retain the insert in the slot. The panel includes one or more attaching features and the retainer includes one or more attaching features to attach the panel and the retainer to each other, thereby retaining the insert in the slot. In a preferred embodiment, the retainer may be heat staked to the panel. The insert may include one or more additional features, such as cording, loops or rickrack to attach the pocket to the panel or the retainer.

Abstract: To provide a seat having a three-dimensional complex undulated cushion body securing hardness in a stress direction and excelling in dispersibility of the stress and durability, and a method of manufacturing the same.

Abstract: The invention is a grid section for a mattress core, wherein springs are mounted back to back on the grid section and wherein the grid section is attached to other grid sections in a two dimensional array to create an interconnected grid array. The grid section is cross shaped with four arms. Each arm has either a male or female tip. The male and female tips of the grid sections fit together to form the mattress grid array.

Abstract: Expandable edge-support members, assemblies, and related methods are disclosed. The expandable edge-support members can be used to provide edge support, including side support and corner support. The expandable edge-support members are suitable for bedding and seating applications as examples. The expandable edge-support members are expandable in length. Thus, the expandable edge-support members can be expanded in length as needed to be utilized to provide edge support for an innerspring having variations in perimeter lengths and different types of innersprings having variations in perimeter lengths. Further, the edge-support members may include a plurality of lateral members, which may be configured to be disposed between adjacent perimeter coils of an innerspring to support attachment to the innerspring.

Abstract: A reversible foam mattress is formed of a foam core and includes a comfort side on one side of the foam core, a support side on an opposite side of the foam core, and side rails formed along longitudinal edges of the foam core. The comfort side includes a first convoluted section with convolutions having a first height, and the support side includes a second convoluted section with convolutions having a second height shorter than the first height.

Abstract: Seat inserts and methods of manufacture are described. An example seat insert includes a fastener to removably couple the seat insert to a bassinet or playard. The example seat include also includes a first base panel having a first length, a first end and a second end and a second base panel having a second length, a first end and a second end. The second end of the first base panel is coupled to the first end of the second base panel. In addition, the first length is longer than the second length so that the first base panel is positioned at a first incline and the second base panel is positioned at a second incline different than the first incline to cause a child occupant to assume a semi-upright position.

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: A bed bug resistant cover for a mattress includes a plurality of panels of fabric material connected by seams that are RF welded. The connected plurality of panels include a first opening for receiving the mattress and a second opening serving as a vent. A zipper assembly is cooperable with the panels of fabric material and RF welded to the opening to close the panels of fabric material over the mattress. A filter is RF welded to an inside surface of the panels of fabric material and covers the vent.

Abstract: A device and method for producing functional pocket spring mattresses, and a mattress produced by the method, in which a predetermined number of pocket springs each prepared by connecting a predetermined number of pocket spring units to each other in the form of a band are arrayed to fit a bed mattress of a desired predetermined size.

Abstract: An apparatus for securing a trim cover to a foam pad includes a base and a platform coupled thereto that defines a working surface for supporting the foam pad thereon. A plurality of actuators project from the working surface. Each actuator is capable of movement away from and toward the working surface and includes a pair of retaining fingers capable of movement between an open and closed position. In use, the retaining fingers grasp a first connecting member on the trim cover and move the first connecting member toward the working surface as the actuators are moved toward the working surface so as to engage the first connecting member with a second connecting member in the foam pad thereby securing the trim cover to the foam pad.

Abstract: A cushion assembly includes a cover having a perimeter panel providing a perimeter height. Spaced apart cover panels extend between the perimeter panels. The perimeter and cover panels together provide a cushion cavity. A cushion includes randomly oriented fibers bonded to one another to provide a core of a batt that has opposing surfaces. In one disclosed example, the fibers are polyester and include an average length randomly oriented in three dimensions. The core has a thickness that is greater than the average length to accommodate the average length in all three dimensions. The batt includes manufactured, tufted and desired design heights. A tuft extends through the cushion to the opposing surfaces to maintain the cushion in the tufted height, which is less than the manufactured height. The cushion is provided with the desired design height with the tufted cushion arranged within the cushion cavity, the desired design height less than the manufactured height and more than the tufted height.

Abstract: In one embodiment, a mattress is constructed of a core having a first side and a second side. A padding layer is positioned at the first side of the core and has a contoured surface and a planar surface. A layer of individual fiberballs is disposed on the planar surface of the padding layer.

Abstract: A flame resistant moisture barrier and a mattress having such a barrier and related methods of manufacture provide mattresses, furniture cushions and other products that provide resistance to flame and moisture.

Abstract: A chair cover for use with a seat includes first and second layers. A pocket formed between the layers holds removable pad. Chair cover rim includes an elastic band to secure cover to a chair. A tether is attached to one of the layers to allow the cover to be easily stored in a compact form.

Abstract: The invention relates to a method for assembling a crash-active head support (1) of a vehicle seat, whereby the structure of the head support (1) is initially assembled from a rear and a front bearing shell and is then upholstered. The rear bearing shell (5) and the front bearing shell (11) are equipped with components (3, 15, 25, 31) and then the equipped bearing shells (5, 11) are rigidly connected together. An impact element (55) is coupled thereto thus forming a quadruple joint.

Abstract: Systems and methods include a spring-coil assembly having non-linear load-deflection characteristics that are substantially similar to foam. In particular, the systems and methods described herein include a first set of encased springs that are in a partially compressed state and a second set of shorter springs. These two sets of springs may be arranged in alternating rows such that the resulting spring-coil assembly displays non-linear load-deflection characteristics similar to foam.

Abstract: The modular supporting element to make mattresses, pillows and the like comprises a body which is elastically deformable in at least one direction of deformation, the body comprising a first portion having a first modulus of elasticity and a second portion having a second modulus of elasticity which is different from the first modulus of elasticity.

Abstract: A method of manufacturing a ventilation diffuser bag includes providing a perforated, occupant facing side of the diffuser bag and an air mover; molding a non-perforated, support facing side of the diffuser bag having an opening to allow air flow therethrough and including an integral air mover support, the air mover support including an endless sidewall extending from the opening for supporting the air mover, the endless sidewall including a retaining edge spaced from the non-perforated side for suspendably retaining the air mover, and a vibration dampening suspension portion; mounting the air mover in the air mover support such that the air mover engages the retaining edge; disposing an air permeable material adjacent the non-perforated side; and permanently connecting edges of the perforated, occupant facing side to edges of the non-perforated, support facing side such that the air permeable material is disposed between the perforated side and the non-perforated side.

Abstract: A method is provided for forming a welt in a single sheet of coverstock by folding and sewing. A second method is provided for forming a welt adjacent a seam formed by sewing two sheets of coverstock together, the method requiring less selvage from one of the sheets.

Abstract: Stepped-edge and side-support members, systems, assemblies, and related methods for an innerspring assembly or other core are disclosed. In one embodiment, an innerspring assembly or core is provided having an interior area of a first height surrounded by one or more exterior, perimeter area(s) of shorter height(s) to provide a stepped-edge innerspring assembly or core. At least a portion of side-support members are placed onto at least a portion of the top surface of the perimeter area to provide edge-support for the innerspring assembly or core. In this manner, a greater portion of the side-support members can be disposed in the sleeping area of the innerspring assembly or core since the underlying perimeter area provides spring support to the side-support members. Further, this support can assist in retention and/or recovery of the shape of the side-support members to further prevent or reduce compression set of the side-support members.

Abstract: A panel for a mattress including first and second fabric layers joined together along their edges and a padding material between said fabrics. The padding material includes at least a layer of resilient foam provided with through-holes. The foam layer is quilted between the first and second fabric layers. A method of manufacturing the panel includes forming a resilient foam body provided with recesses, horizontally cutting a plurality of single layers in the body in the recesses portion to result in at least one layer with through-holes, sandwiching at least one of the single layers provided with through-holes in each panel between the first and second fabric layers.

Abstract: An apparatus and process for causing excess covering material at a workpiece corner to be gathered, folded and secured to a back side of the panel. A corner tucking apparatus includes a gathering plate positioned adjacent a positioning structure, and moves inwardly across the back side of the workpiece, from the corner, to gather and fold the corner flap. The gathering plate has a generally V-shaped notch which causes excess material to be gathered together as the plate moves inwardly. The gathered material upon reaching the apex of the notch is folded downwardly into contact with the back side of the workpiece. A securing structure which is carried inwardly with the gathering plate is then activated to fixedly secure the folded flap to the pad or workpiece.

Abstract: An elongated edging is provided for use in a method of upholstering a chair element with a perimeter edge. The edging has a pair of sides and a top portion, with a slot defined between the sides for receiving the perimeter edge of the chair element. A flange extends outwardly from the outward face of the side of the edging and defines a recess between an upper side of the flange and the outward face of the side of the edging. A portion of upholstery is attached to the chair element using fasteners which are positioned in the recess.

Abstract: A vehicle seat includes a backrest and a seat part, at least one of which has a structural element forming a cavity. A filling is disposed in the cavity and configured to influence the stability and/or the deformation behavior of the backrest and/or the seat part. The filling comprises a foam support and a foam material that at least partially surrounds the foam support.

Abstract: A cushion unit includes shell having a first cushion retaining portion and a second cushion retaining portion that are demarcated by a hinge-seam including a fastener portion. The fastener portion is secured to an inboard surface of the shell. According to an embodiment, the cushion unit includes a cushion member affixed to an inboard surface of the shell. According to an embodiment, the fastener portion is secured directly to an outboard surface of the cushion member and secured indirectly to an inboard an inboard surface of the shell. According to an embodiment, the fastener portion is secured directly to an inboard an inboard surface of the shell. A method for manufacturing a cushion unit is disclosed. A method for providing a cushion unit is also disclosed.

Abstract: A chair frame is formed of a continuous and endless loop that includes ground engaging loops (or legs), fabric seat receiving loops, which also act as arm rests, and a back loop which defines the chair back. Fabrics are fixed to the seat loops and back loops to form the seat and back respectively of the chair.

Abstract: A symmetrical pressure relief foam mattress includes an upper foam layer placed on a zoned foam layer. A plurality of cylindrical holes are distributed throughout each of a first, a second and a third lateral region of the zoned foam layer. The first lateral region is less than twelve inches wide and has a middle that is within eighteen inches of the top of the zoned foam layer. The third lateral region is also less than twelve inches wide and has a middle that is within eighteen inches of the bottom of the zoned foam layer. The second lateral region has a middle disposed at the center axis of the zoned foam layer. The middle of both the first and third lateral regions is about fifteen inches from the edge of the mattress regardless of which end the consumer chooses to use as the head of the mattress.

Abstract: A spring mattress for beds is disclosed. In at least one embodiment, the spring mattress includes a plurality of strings which are interconnected side by side and include a continuous casing material with a plurality of separate pockets with coil springs enclosed therein. Moreover the casing material for at least some pockets is at least substantially airtight, thus providing a resistance to air being pressed out when the springs of the mattress are loaded, which, when subjected to a uniform load during a transition period, results in a gradually increasing depression of the spring to its depressed state. This results in a comfortable mattress, into which the user sinks gradually and which thus is comfortable and safe and allows the user to move easily. A corresponding method and device for manufacturing such a mattress are also described.

Abstract: A vehicle seat is provided. The vehicle seat includes: a planar elastic body that has a frame body provided in a periphery of the planar elastic body, the planar elastic body stretched to the frame body; a cushion member disposed around the planar elastic body; and a backbone member, wherein a supporting surface configured to support a seated person is formed by the planar elastic body and the cushion member, the planar elastic body is assembled to the seat by fixing the frame body to the backbone member, and the cushion member is disposed to be overlaid on the periphery of the planar elastic body at a supporting surface side, the cushion member is covered by a skin material that is attached on the planar elastic body at the supporting surface side.

Abstract: A method for manufacturing a chair seat, wherein borders of the chair seat is injection molded by two steps, comprises following steps: a. preparing net cloth, inner border injecting mold, outer border injecting mold, plastic and gun screw; b. injecting inner border: warming up inner border injecting mold, simultaneously heating up the plastic, and injecting the plastic into the inner border injecting mold when its temperature reaches the injecting temperature; c. installing the net cloth: cutting out the net cloth according to the size of the inner border, impacting the edge of the net cloth into the inner border by the gun screw by hand, and then cutting redundant net cloth; d. injecting outer border: inserting the inner border with impacted net cloth into the outer border injecting mold, and injecting the plastic into the outer border injecting mold when its temperature reaches the injecting temperature.

Abstract: A tape-shaped engaging member F for fixing an upholstery material to seats, which includes a hook surface fastener composed of a double Raschel-knitted base fabric 1 and projecting mushroom-type fastening elements 2 on the surface of the base fabric and a foamed resin layer 3 integrally united to the back surface of the hook surface fastener, and a method of producing a resin molded article equipped with the engaging member. The tape-shaped engaging member is easily set to a mold, has good in-plane flexibility and deforms in good conformity with three-dimensionally curved surfaces.

Abstract: A trim cover is inwardly hung into inward hanging grooves of a vehicle seat. The vehicle seat includes a cushion pad having right and left bank faces. A number of workpieces are cut out. Portions of the cut out workpieces are gathered. There portions correspond to lateral inward hanging ends located at lateral end portions of inward hanging margins of the cut out workpieces. The gathered portions are sewn so as to curve, into inward hanging directions, the inward hanging margin portions of the workpieces thereby contracting obverse surface materials of the workpieces. Inward hanging members are mounted to the trim cover. the inward hanging members are inserted into longitudinal inward hanging grooves. Fasteners engage the inward hanging members and engagement members of the cushion pad.

Abstract: A low-profile mattress comprises an inner spring core having a plurality of spring coils and having an upper and lower surface. The mattress further includes a padding layer disposed on the upper surface and a quilting layer disposed over the padding layer and having an exterior layer of a liquid resistant material, wherein the innerspring core padding layer and quilting layer are dimensionally adapted to be less than eight inches in height.

Abstract: A stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.

Abstract: A spring mattress is described, including a plurality of strings interconnected side by side. Each string includes a plurality of continuous casings and, enclosed therein, coil springs. Moreover, between at least some of the springs in at least one of the strings a slot is arranged which opens towards the upper or lower side of the mattress. It is preferred for the springs between which the slot is arranged to be separated with an intermediate separation distance, which separation distance exceeds about 10% of the diameter of the largest turn of the adjoining springs. In addition, it is preferred for the casing portions to be arranged at the ends of the spring to be moved towards each other, through the spring, and connected to each other by at least one connecting device.

Abstract: A space saver pillow system comprises a space saver pillow and a bag. The space saver pillow includes a fill and a covering surrounding and enclosing the fill. The fill of the space saver pillow is adapted to generally rebound back to its natural state after being compressed. The bag encloses the space saver pillow and an amount of air. The space saver pillow enclosed in the bag is compressed no more than about 80% of its original size.

Abstract: A patient support includes a layer of fluid pressurized bladders, the bladders each having a chamber and an upwardly facing surface for facing and supporting a patient, and a cover over the layer of fluid pressurized bladders. Respective bladders in at least a group of the bladders each have a resilient body in its respective chamber to reform the shape of the respective bladder when a compression load on the respective bladder is removed wherein the pressure in the respective bladders is generally maintained without a powered supply of air. The cover has an upwardly facing patient surface and a bladder layer facing surface, with the patient surface for forming a patient support surface on the support, and the bladder layer facing surface for lying on the upwardly facing surfaces of the bladders.

Abstract: At least one embodiment of the present invention relates to a method of manufacturing an acoustically tuned vehicle seat assembly comprising providing a cushion supported on a frame, and securing a non-cloth trim material over the cushion, the non-cloth trim material having at least one slitted region having a plurality of scored slits.

Abstract: The invention relates to a suspension pocketed spring system containing steps of manufacture of standard pocketed springs (10) manufactured for use in inner construction systems used to provide flexibility between platforms/layers where to be located and separate connection of short pocketed springs (20) to each other in a manner to form a space (23) and manufacture method of it

Abstract: A backrest for a vehicle seat is disclosed. The backrest has a support fastened to a back plate and at least one sleeve fastened to the support. A foam material and a fabric are placed around the support, the fabric having at least one cutout. An insertion sleeve of a component is pulled through the cutout and over a lower end of the headrest sleeve. The component, such as a screen, is fastened at an end to the backplate and/or to the support.

Abstract: A seat cushion system includes a seat cushion assembly and at least one supplemental pad attached to a portion of the seat cushion assembly. The seat cushion assembly and the at least one supplemental pad include chambers that may be filled with a fluid to provide isolation between a user and a wheelchair or other seating structure.

Abstract: An aspect of the present invention provides a sewing structure of a facing sheet member for covering a vehicle seat. The facing sheet member is formed by sewing a plurality of facing sheet pieces together at respective end parts thereof. Each of the facing sheet pieces includes a surface member and a pad member laminated on the surface member. In the end part of each of the facing sheet pieces, at least a part of the pad member is removed or the pad member is not laminated on the surface member. The plurality of facing sheet pieces are sewed together using the surface members at the end parts thereof.

Abstract: An aircraft passenger seat configured in accordance with an embodiment of the invention utilizes composite materials to achieve significant weight savings relative to conventional seat designs. The seat includes one or more lightweight composite support legs, a lightweight composite seat pan, and a lightweight composite seat back structure. The support legs are coupled to the seat pan, which is in turn coupled to the seat back structure. The support legs utilize composite frame elements that are formed as continuous compression molded composite extrusions. The seat pan includes composite fore and aft cross beams that are also formed as continuous compression molded composite extrusions. The aft cross beam includes a rear flange that serves as a flexible “hinge” for the seat back structure. The seat can leverage producible and relatively inexpensive composite manufacturing techniques such that the seat can be economically produced for use as an economy class seat.