Abstract: In at least one embodiment, the present invention provides a vehicle seat assembly comprising a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, with the cushion having a plurality of intrusions extending from the “A” surface towards the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 8% to 25%.

Abstract: The embodiments described herein generally relate to a system and method for joining a detachable fabric sheet to a cover through the use of one or more corresponding fastening or temporary joining mechanisms located on the cover and fabric sheet. In an embodiment, the cover includes one or more mechanisms to align and/or secure a filling material to the cover, as well as one or more fastening or temporary joining mechanisms for attaching the detachable fabric sheet to the cover. Methods and systems are provided for detachably joining the fabric sheet to the cover, for creating a multi-layer unit of a cover and detachable sheets, as well as for aligning and securing the filler to the cover. A method is also provided for manufacturing the integrated bedding cover system.

Abstract: There is disclosed a mattress comprising a first border member configured to define an upper periphery of the mattress and a second border member configured to define a lower periphery of the mattress. At least two spring assemblies are positioned within the first and second border members so as to extend between the first and second border members. Each spring assembly comprises an array of coil springs and each spring assembly is positioned such that the coil springs of one spring assembly are not directly connected with coil springs of any other spring assembly.

Abstract: There is provided a seat cover for accommodating a child safety chair upon a seat. The seat cover comprises a lower protective member which is disposable upon a seating portion of the seat. This lower member can accommodate the child safety chair when positioned in a rearward-facing direction to prevent it from permanently compressing the seating portion. The seat cover further comprises an upper protective member that is disposable against a seat-back portion of the seat. This upper member is selectively attachable with and detachable from the lower member. By doing so, the upper member can further prevent the chair from permanently compressing the seat-back portion when it is repositioned in a forward-facing direction and placed in contact therewith.

Abstract: A center console (20) includes a first panel (32) having a first upper surface (76) and a first padded portion (28). The first padded portion (28) includes a first outer cover (54). The first outer cover (54) is mounted to the first panel (32) such that a first cavity (56) is formed by at least a portion of the outer cover (54) and at least a portion of the upper surface (76). The first padded portion (28) also includes first padding (56) located, in the first cavity (56).

Abstract: A method and apparatus for fabricating upholstered furniture articles and components is disclosed. The method employs an assembly line with work stations. A selected beginning part such as a wooden frame or skeleton is transported along the assembly line using a specially configured fixture or jig to hold the frame or skeleton. At selected work stations, the fixture can be rotated or tilted depending upon the work to be performed. A locking arrangement secures the fixture to the track at each work station.

Abstract: Seat pads of the present invention are sewn by hollow weave, and includes skins having single sheets of woven cloth integrally continuously having single layer portions and laminated layers portions in a shape of a hollow bag, and cushioning members enclosed at inner portions of the laminated layers portions and having a shape the same as that of the laminated layers portion and having an elasticity, the laminated layers portions are formed at portions of the single sheets of woven cloth intended to support the physical body of a seated person, the cushioning members are provided with predetermined thicknesses, the laminated layers portion are formed with recesses and projections of the same shape projected by a predetermined amount from head and tail faces of the single layer portions, and attachably and detachably mounted to a seating face of a seat, a recessed portion constituting a shape the same as that of the laminated layers portion is formed at a position of the seating face of the seat facing the lam

Abstract: A spring mattress is disclosed including a plurality of strings interconnected side by side, each string including a plurality of continuous casings and each casing including a coil spring. Further, in at least one embodiment, at least one of the casings in at least one of the strings includes a plurality of stretch openings into the interior of the casing, wherein at least some of said stretch openings are displaced in relation to each other in a lengthwise direction of the spring. At least one embodiment of the present invention also relates to a method and a device for manufacturing of such a mattress, as well as to a bed adapted for such a mattress.

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 mattress core unit, such as an innerspring, is placed inside a foam envelope, which in turn is covered with fabric. The side and end rails of the envelope overlap the bottom panel, to provide good support for all edges of the mattress. The top panel of the envelope overlaps the side and end rails. To make a reversible mattress, an overlapping bottom foam panel is used. The method simplifies matress construction, reduces the number of required stock keeping units, and provides a comfortable, yet firm, feel at the edges of the mattress.

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 method for the production of a fixing piece (12, 36) serves for fixing of covering material to cushion pieces for vehicle seats. A profile body (12) is connected to a separately produced sewn tag (36) which at least partly engages in a housing opening (34) in the profile body (12). The profile body (12) and the sewn tag (36), at least in the common jointing positions thereof, are predominantly made of plastic materials. According to the present invention, the known welding and glued connecting applications can be further improved such that the production method can be rapidly carried out with low production costs and without additional materials. A strong connection can be achieved, conforming to more stringent environmental aspects.

Abstract: An actively ventilated vehicle seat includes a lower air-impermeable seat cushion or backrest part, an air-permeable intermediate layer made of a spacer fabric and an upholstered cover. The vehicle seat is divided into upholstered areas which are delimited from each other by seams anchored at the air-impermeable seat cushion. Air bridges are provided which extend transversely to the seams for connecting the intermediate layer between the individual upholstered areas. An unobstructed seat ventilating system and a permanently secure attachment of the seams are achieved in a simple manner in terms of production and without affecting the seating comfort in that the air bridges are integrated all around into the air-impermeable seat cushion and the seams are anchored above the air bridges in the air-impermeable material of the upholstered part covering the air bridges.

Abstract: An improved cushioning apparatus having a plurality of individual pockets containing an improved filler material comprising granular viscoelastic foam, said apparatus further comprising a top buffering layer for improved stability and comfort.

Abstract: A system for automatically stretching and stapling a foundation cover to a spring unit for a foundation, including a support table for supporting the foundation and cover, and a series of stretching/stapling assemblies or units positioned along the support table. The stretching/stapling assemblies include a series of tension applicators that engage and pull the cover taut against the sides of the spring unit of the foundation, while staplers are lowered into engagement with the cover and foundation frame, automatically stapling the cover to the sides of the foundation frame.

Abstract: A method and apparatus for assembling box springs for use in bedding applications. The apparatus comprises a base for supporting a frame and a spring unit, a framework with a plurality of tools coupled thereto. Each tool has an associated module adjuster coupled thereto. A vertical drive mechanism provides relative movement between the tools and the base where the tools may be disposed between a first vertical position and a second vertical position. A horizontal drive mechanism provides relative horizontal movement between the tools and the base. Each tool is configured to secure a respective module of a row of the spring unit to a corresponding target location on the frame when disposed in the second vertical position and each module adjuster is configured to align a respective module with a corresponding fastening location when the tool is disposed in the second vertical position.

Abstract: A process and apparatus for forming a mattress. A border material is fed through a sewing station to form a hem. The same material is fed through the sewing station again, at a different elevation to form a second hem and an attachment gusset. The hemmed gusset and border material then is preferably subjected to a ruffling process to form a series of pleats about the corners of the mattress border. The perimeter of the border is then closed, and the finished border is placed over a set of mattress springs and fixed in place.

Abstract: A high-back automobile seat having an opening defined by the seat's rear surface. The opening allows mounting of utility or entertainment components for use by a passenger behind the high-back seat. Entertainment components such as a video screen or an integrated DVD player/screen may be mounted for viewing enjoyment. A formed seat bun with the opening provides the space for mounting of such components. The formed seat bun may be prewired to allow easier installation of electronic components. An area about the opening may be contoured to provide sufficient depth for flush mounting of components.

Abstract: Apparatus for manufacturing a bedding foundation having a base and a wire grid of support wires comprises at least one vertically moveable staple gun having a staple head and a wire positioner associated with the staple head, the wire positioner being configured to engage one of the support wires and to position the one support wire relative to the staple head such that upon activation, the staple gun staples the one support wire in the intended position to the base.

Abstract: An apparatus for attaching an item to load-bearing fabric including male and female strips that snap together on opposite sides of the fabric. The male strip is attached to the item to be secured to the fabric, and includes male prongs that are pushed through the weave of the load-bearing fabric. The female strip preferably defines a series of receptacles that snap onto the male strip. The male and female strips are elongated strips formed from a molded thermoplastic or other formable material. In a preferred embodiment, the male prongs include barbs and the receptacles include angled fingers that act as a snap, such that the barbs of the male prongs can easily be pressed through the fingers, but are retained once in place.

Abstract: Apparatus for manufacturing a bedding foundation having a base and a wire grid of support wires, comprising at least one vertically moveable staple gun having a staple head and a wire positioner associated with the staple head, the wire positioner being configured to engage one of the support wires and to position the one support wire relative to the staple head such that upon activation, the staple gun staples the one support wire in the intended position to the base, wherein the wire positioner has a fixed positioning element and a movable positioning element, the elements adapted to position the one support wire therebetween.

Abstract: A cushion subassembly includes a support, a cushion of non-woven polymeric (PET) or PETE fibers with a formed edge that wraps over an edge of the support, and an upholstery sock pulled onto and covering the support and the cushion. The formed edge has sufficient structure to retain the cushion in place on the support as the upholstery sock is pulled onto the support. A back support shell supports the cushion assembly, and has first fasteners that engage in a first direction and second fasteners that prevent disengagement. The cushion assembly is stressed during assembly, especially at corners, but is thermally stress-relieved after assembly to relax the polymeric fibers and the upholstery sock to a state of minimized balanced tension. The back support shell includes a shallow depression on its face. The cushion fills the depression sufficient to eliminate loose fabric but provides a same force deflection curve across its shape.

Abstract: A mattress includes a plurality of individual foam blocks which are secured together using one or more plastic fasteners to form a five-sided foam encasement. A spring unit is fittingly disposed within an interior cavity defined by the foam encasement. One or more top layers of foam rubber are mounted on the foam encasement over the spring unit and are secured thereto using additional plastic fasteners. An outer layer of quilted cotton material is sewn over the foam encasement and top layers of foam rubber to yield the finished one-piece mattress. As can be appreciated, the outer periphery of the mattress is defined by foam material, which is substantially rigid in its construction, rather than the spring unit, which is highly susceptible to warping. In this manner, the foam material serves to preserve the shape of the outer periphery of the mattress over time.

Abstract: A pillow top mattress is made by first folding a mattress core border strip lengthwise to form at least one integral pillow top border, cutting diamond-shaped notches out of the folded edge, and sewing the free edges of the notches together to form mitered corners. The strip is cut to length, and after its ends are joined together to form a band, it is pulled over the mattress core. The border strip is then secured to the core material, and pillow top insulation is added before a pillow top panel is sewn to the free edge of the border strip.

Abstract: A vehicle seat has a seat bottom and seat back. The seat bottom can have a ventilated insert located between the seat upholstery and the seat cushion. The inset can be in fluid communication with the cabin space of the vehicle. In one arrangement, the insert has a cover with holes and a body. The cover and body cooperate to form a plurality of plenums for passing air through the insert. A fluid system can deliver air to the insert so that the air passes through the plenums and directed out of the holes in the cover. The air then flows out of the vehicle seat to control the climate around the person in the seat. The insert can also be used to remove air near the seat by drawing air proximate the seat into the insert. The air can then pass through the insert and is delivered to the fluid system.

Abstract: An improved cushioning apparatus having a plurality of individual pockets containing an improved filler material comprising granular viscoelastic foam.

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 fastener apparatus is provided for securing a plurality of modules to a frame.

Abstract: A method of assembling an upholstered furniture piece comprising decorative fasteners comprising providing an underlayment material layer, a foam material layer and a covering material layer. The foam material layer is positioned between the underlayment material layer and the covering material layer. The covering material layer extends beyond the underlayment material layer and the foam material layer. Fasteners are used to fasten the underlayment material layer, the foam material layer and the covering material layer together forming a layered component. A template may be used to guide positioning of the fasteners. The fasteners are decorative fasteners. Excess covering material that extends beyond the fasteners is stretched around the edges of the layered component and is affixed to a bottom surface of the layered component, thereby forming a layered assembly. The layered assembly is affixed to an upholstered furniture piece.

Abstract: An office chair is provided having a contoured back assembly comprising a back frame and a suspension fabric. The fabric is attached to the back frame through a spline wherein the back frame has a three-dimensional contoured shape formed by overlapped frame rings with the fabric being joined thereto by a spline. The fabric is secured to the frame by a machine wherein the fabric is first stretched from the outer edge of the fabric and then is clamped to a frame surface in the pre-tensioned or pre-streched condition. The fabric edges are allowed to hang loose and then fixed in the frame by a spline. Once secured, the fabric is unclamped from the frame.

Abstract: At least one major surface of the core is covered with an inner layer of insulation, and at least one outer layer of material. The outer layer is secured to the inner layer by inserting flexible filament type fasteners through the hollow needle of an installation tool. If the core is made of foam, filamentary fasteners may also be used to secure the inner layer. The insulation layers are ultimately covered and secured in place by a fabric panel which conceals and secures the other components. Filamentary fasteners may also be used to secure a pillow top edge or a top panel to the mattress.

Abstract: A chair construction includes a chair frame with a seat portion and a back portion and a flexible envelope that encompasses the chair frame. The envelope includes first and second layers having a first selected width between first left and right edges. The first and second layers are constructed of a slingable material. A third layer constructed of a non-slingable material and has a second selected width between second left and right edges where the second selected width is shorter than the first selected width of the first and second layers. The first and second left and right edges are aligned and the layers are secured together proximate the left and right edges to form the flexible envelope. When the envelope is positioned over the frame, the third layer is stretched a greater distance than the first and second layers, such that the non-slingable layer remains taut.

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.

Abstract: A method produces a flexible shaped strip (18), made of plastic, for fixing cushion cover (12) to a cushion component (10). The cushion component is formed of a foam material and includes a longitudinal channel (20) for insertion of the shaped strip (18). The shaped strip has, at least partly, a slip preventer to increase the tear resistance form the cushion component (10). The anti-slip component or slip preventer is made of a plastic softer than that used for the shaped strip (18), and is, at least partly, arranged around the outer surface of the shaped strip.

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 mattress and a method of manufacturing a mattress are disclosed. The mattress includes a mattress core, a side rail joined to the mattress core by a one or more adhesive patches, optionally a deck applied over an area of the mattress core and joined to the mattress core by adhesive patches, and an upholstery layer defining a sleep surface applied over the deck or the mattress core and joined to the deck by adhesive patches. The adhesive patches have a bonding strength sufficient to maintain a relative position between the various mattress components at least during assembly of the mattress. The upholstery layer is permanently secured to the side rail by, for example, sewing or stapling.

Abstract: Spring cushions having slow-acting pocketed spring cores characterized by the individual springs of the cores being sealingly pocketed within semi-impermeable fabric material and a method of making such pocketed spring cores.

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: A head restraint includes a head restraint post having at least a pair of leg portions, a cross member interconnecting the leg portions, and a rigid support member connected to the cross member of the post without retaining the leg portions, where the rigid support member does not rotate about the cross member. By virtue of the rigid support member being connected to the cross member without retaining the leg portions, the leg portions are provided with sufficient flexibility for easy assembly with a seat back and smooth height adjustment. A compressible pad further can be arranged over the post and rigid support member to complete manufacture of the head restraint. The leg portions of the head restraint are configured to be received in at least one of a seat back, an interface in the seat back, or another part of a motor vehicle.

Abstract: An automobile interior component includes a substrate component having a seam-mating section. The seam-mating section has a welt protrusion-mating channel that is useful for accurately position a welt strip. The automobile interior component further includes a trim cover having at least one join seam. A welt strip having a welt protrusion section is attached to the trim cover. The welt strip allows positioning of the trim cover over the substrate in that the welt protrusion section is positioned in the welt protrusion-mating channel. A method for manufacturing the automobile interior component is also provided.

Abstract: A flexible support structure of a seat cushion, such as a wheelchair cushion, has an upper surface with a support contour having relief areas for establishing relatively less pressure on skin adjacent to bony prominences of a user's pelvis and having a support area for establishing relatively more pressure on skin covering a tissue mass spaced from the bony prominences. A slit is formed in the rear corner of the support structure and an insertion member is inserted into the slit to change a position of the support area to thereby adjust the support contour for better support of the pelvic area. A cover encases the support structure to resist outward deformation of the support structure. The cover has an extension portion that expands the cover at the rear corner to increase a dimension of the cover to encase an increase dimension of the corner caused by the insertion of the insertion member.

Abstract: The invention relates to a vehicle seat, in particular for a motor vehicle, wherein the vehicle seat comprises padding and a profile or panel which comprises a padding channel for the fastening of the padding and/or of a cover, and wherein the padding channel comprises a tab which protrudes into the padding channel in such a manner that it increasingly narrows the latter in one section (V) in the longitudinal direction of the padding channel.

Abstract: A reclining office chair is provided. The reclining office chair includes a swivel base and an extendable foot panel. The extendable foot panel may be extended by a user sitting in the chair my mechanically engaging at least one of the arm rests of the chair.

Abstract: A mattress frame that occupies a small volume and can be used by a recipient without having to assemble the frame. The frame has four connected sides and is made of foam. The frame is rectangular in shape and has two longer sides and two shorter sides. The two shorter sides are folded in a U shape so that a bow-tie-shaped frame results. The bow-tie-shaped frame is rolled and packaged in a container. The frame can be rolled to form a spiral or an M-shape. A recipient of the rolled frame removes the frame from its packaging and the frame expands to its intended shape.

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 mattress or seating spring core assembly and method of manufacture which comprises interconnected rows of coil springs wherein each row terminates in a cut wire end which is bent inwardly into one of the end coils and in which the spring core assembly is surrounded on all sides by foam panels and is devoid of any border rods.

Abstract: A method of manufacturing an automotive door armrest is provided and comprises molding an armrest support surface into a lower door panel. A frame assembly is formed to comprise at least one through socket having an open upper socket face and an open lower. The frame assembly is overmolded such that an overmold surface is formed over the open upper socket face. A foam bun is inserted into the lower socket face. The frame assembly is mounted onto the armrest support surface such that the foam bun becomes secured within the at least one through socket. The frame assembly is affixed to the lower door panel.

Abstract: A fastening apparatus and method is provided for securing a plurality of modules to a frame.

Abstract: A head restraint assembly comprising a frame assembly including a retention member. A pillow coupled to the frame assembly with the pillow configured to allow access to the retention member. A cover assembly having a back end and a front end envelopes and conforms to the shape of the pillow with the cover assembly including a flat strip member coupled to the back end and a barb strip member coupled to the front end of the cover assembly. The flat strip member and the barb strip member couple with each other in the retention member closing the cover assembly over the pillow. Also, a method for making a head restraint assembly.

Abstract: A mattress and a method of manufacturing a mattress are disclosed. The mattress includes a mattress core, a side rail joined to the mattress core by a one or more adhesive patches, optionally a deck applied over an area of the mattress core and joined to the mattress core by adhesive patches, and an upholstery layer defining a sleep surface applied over the deck or the mattress core and joined to the deck by adhesive patches. The adhesive patches have a bonding strength sufficient to maintain a relative position between the various mattress components at least during assembly of the mattress. The upholstery layer is permanently secured to the side rail by, for example, sewing or stapling.