Abstract: Apparatus for manufacturing pillows, comprising: at least one first bobbin of a first fabric and a second bobbin of a second fabric, means adapted to place the first fabric on the second fabric along their advancement path, means configured to drag the fabrics, a pair of side welding devices for welding the side edges of first and second fabrics, a transverse welding device adapted to weld the fabrics found in a tubular envelope transversally to the advancement path for forming a pillowcase, a press for pressing the first fabric onto the second fabric when the length of the pillow reaches the desired length, means adapted to insert material inside the pillowcase, means for cutting the fabrics welded by the transverse welding device to separate the pillow from the successive pillow.

Abstract: A method, apparatus, and seating product that include a seat deck assembly with a tensioned fabric decking are described. The seat deck assembly includes one or a pair of frame rails attached along opposite edges of the decking. The decking includes an elastomeric textile. The decking or a first of the frame rails is attached to a first side of the frame. The second of the frame rails is placed in a rigid fixture. A force is applied by an actuator to the frame to move the second side of the frame toward the second frame rail and to stretch the elastomeric fabric. The second frame rail is couple to the second side of the frame and the assembled frame is removed from the fixture. Cushions, padding or an upholstered covering can complete embodiments of the seating product.

Abstract: A mattress (22) having a foam core (8) completely extends to the perimeter edges of the mattress wherein side walls (15) of the foam core are compressed inward and held in place using a preferably non-woven strip of fabric (21) or similar non-elastic or non-stretchable material that is wrapped around the side walls of the foam core. A method of wrapping the foam core allows corners (5) of the foam core to be formed under the inward pressure of the non-woven fabric, thereby creating a strong perimeter for the mattress that prevents outward pressure against the sidewalls created by the downward pressure of an individual lying on the mattress from flattening of the mattress by providing more upward pushback against the individual. An optional layer of micro-coil springs (2a) may be located within the foam core to provide more buoyancy and springiness in the mattress.

Abstract: The invention relates to the upholstery of a seat element for a motor vehicle and to the method of creating it, in which method a foam support block is produced to fit a frame element; a cover element is created by cold-forming a foam sprayed onto a polypropylene substrate and attached on the reverse side of a textile material in the form of a skin or synthetic material to define the visible shape of the seat element; and the cover element is attached to the support block.

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: 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: A method of producing a stitched perforated sheet material including providing a sheet material (3) with a perforated region 4 and an unperforated region (5). The sheet material is then stitched in the unperforated region, but adjacent to the perforated region. This gives an overall perforated appearance whilst avoiding the problems associated with stitching through a perforated material.

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: There is provided a long-life and strong cover material terminal treating member in which the terminal treatment of a cover material is easy to perform, and the terminal of the cover material is less liable to be taken away by a force from the outside, and which can withstand a long-time use. The cover material terminal treating member 10 for a seat part in which a cushion material 23 is covered with a cover material 24 includes a retaining plate 17 fixed to the terminal of the cover material 24a and a retaining clip 11 for storing the retaining plate 17. The retaining clip 11 includes a first wall part 12 fixed at a position different from the terminal of the cover material 24a, a second wall part 14 facing to the first wall part 12, and a connecting part 13 for connecting the two wall parts 12 and 14 to each other. In the end part of the second wall part 14, a retaining claw 16 bent at an acute angle and being in contact with one end side of the retaining plate 17 is erectingly provided.

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 member with skin includes a substrate, and a skin. The skin includes a covering portion for covering the substrate on the front surface's side, and an anchoring portion for engaging with the substrate's rear-surface periphery. The skin has a covering surface being formed as a concaved planar shape, and an exposed surface being formed as a convexed planar shape. The anchoring portion is disposed successively to the covering portion's periphery, and extends inward toward the covering portion. The skin is made of soft material, and is molded independently of the substrate. Before being assembled with the substrate, the skin includes the covering portion whose covering surface is formed as a convexed planar shape, and whose exposed surface is formed as a concaved planar shape, and the anchoring portion is placed more outward than the covering portion's periphery lies.

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 furniture construction and a method of placing a section of fabric in tension on the furniture construction includes providing a pair of rigid members each having a slot extending along one side. A rigid edge portion is provided on opposite sides of the section of fabric. Each rigid edge portion is then inserted into the slot of each rigid member such that the fabric overlies an adjacent side surface of each rigid member. The rigid members are then moved in opposing directions thereby place the fabric in tension. The edge portion of the fabric is sufficiently rigid to retain the fabric within the slot and thereby retain the fabric in tension. The rigid members are then secured to the furniture construction.

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: 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: 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 about its periphery wherein the back frame has a three-dimensional contoured shape formed by overlapped frame rings with the fabric being joined thereto. 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 by a front frame section in the pre-tensioned or pre-streched condition. The fabric edges are allowed to hang loose and then fixed in the front frame section. Once secured, the fabric is unclamped from the front frame section, and then this sub-assembly is affixed to the rear frame ring to complete the assembly of the back 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: An attachment structure for a load bearing fabric. The attachment structure includes interfitted inner and outer rings. The outer ring includes a fabric leg 74 carrying a load bearing fabric. The inner ring defines a channel receiving the fabric leg 74. The inner ring and outer ring are configured to stretch the fabric upon insertion of the fabric leg 74 into the channel. The present invention also provides a method for securing a load bearing fabric to a support structure, generally including the steps of (a) providing an outer ring having fabric leg 74, (b) attaching a section of load bearing fabric to the fabric leg 74, (c) providing an inner ring having a channel adapted to receive the leg of the outer ring and (d) installing the outer ring to the inner ring by inserting the leg into the channel, the insertion forcing the fabric down into the channel and stretching the fabric to the desired tension.

Abstract: An apparatus for facilitating assembling of a covering sheet onto a cushioned padding for a seat, the covering sheet being formed into a three-dimensional shape and having tensioning cords provided therein, the cushioned padding having a central portion, bulged portions formed at both sides of the central portion, and grooves formed in the central portion, the tensioning cords of the covering sheet being to be received in the grooves of the cushioned padding at the time of fastening of the covering sheet to the cushioned padding, and being to be fastened to the cushioned padding, the apparatus including a base table, a supporting member mounted on the base table for receiving and supporting the cushioned padding at the time of the assembling of the covering sheet onto the cushioned padding, hooking arms arranged at both sides of the base table for causing the bulged portions of the cushioned padding on the supporting member to be pulled away from each other and causing the grooves of the cushioned padding to

Abstract: An attachment structure for a load-bearing fabric including an expandable carrier secured to an un-stretched load-bearing fabric. To attach the carrier to a support frame, the carrier and fabric are stretched together to desired shape and secured to the frame. An indexing system registers the carrier and frame and optionally stretches the fabric a predetermined amount. The present invention also provides a lip that flexes in one direction and maintains the fabric in a stretched condition in another. A tool that joins the carrier and frame generally includes a drive roller and a primary roller adapted to move toward one another and join a carrier and the support frame disposed therebetween. The tool may include alignment rollers near the primary and drive rollers to track along and align the carrier and frame.

Abstract: A material application system for applying a panel of material to a framework with a shoe for retaining the framework, a nest, opposed mechanisms for retaining opposite portions of the panel of material traversing between the shoe and the nest, an arrangement for selectively moving the shoe and the nest into and out of an engaged position wherein the panel of material is sandwiched between the shoe and the nest and a disengaged position, and an arrangement for inducing an attachment of the panel of material to the framework. The opposed mechanisms can be clamping mechanisms, which can be segmented and individually moveable to enable variable pretensioning. A contoured deflection control member can alternatively produce variable pretensioning. A pressing arrangement with a tooth member can press a locking spline into a groove in the framework to secure the material.

Abstract: An apparatus (1) is described for upholstering components of chairs, armchairs, or the like, in particular backrests and/or seats having a sandwich structure (11) with a covering layer (12) fitted so as to cover a frame (14) at least partially, the apparatus comprising at least one stapling gun (8), a support table (10a) for the sandwich structure (11), means (16) for compressing the sandwich structure (11), and a robotic arm (4) on which the stapling gun (8) is mounted, as well as means for controlling the robotic arm (4), the control means being arranged to guide and operate the stapling gun (8) along a stapling path defined peripherally on the sandwich structure (11).

Abstract: A method for assembling a case (5), such as integral play station, a simple screen for a DVD reader or for a play station, a loudspeaker, on a cushion (2) such as a headrest or a set back cushion, fitted with a protection cover (4) includes fastening the case (5) directly on the protection cover (4), before mounting the cover (4) on the cushion (2).

Abstract: A seat assembly machine includes an independently adjustable alignment mechanism. A seat holding mechanism secures a seat frame in place relative to a fabric cover that is supported on another portion of the machine. An independently moveable alignment mechanism includes support posts that are received through openings in the cover and into corresponding receiver portions of the seat frame to properly align those components. After proper alignment is verified, the seat frame is inserted into the cover. The adjustment mechanism is normally biased toward the seat frame holding mechanism and movement of the seat frame holding mechanism overcomes the bias on the alignment mechanism so that the alignment mechanism selectively moves with the seat holder mechanism during an assembly process. The independently positionable alignment mechanism facilitates assembling a variety of seat types using a single machine.

Abstract: An attachment structure for a load bearing fabric. The attachment structure includes interfitted inner and outer rings. The outer ring includes a fabric leg 74 carrying a load bearing fabric. The inner ring defines a channel receiving the fabric leg 74. The inner ring and outer ring are configured to stretch the fabric upon insertion of the fabric leg 74 into the channel. The present invention also provides a method for securing a load bearing fabric to a support structure, generally including the steps of (a) providing an outer ring having fabric leg 74, (b) attaching a section of load bearing fabric to the fabric leg 74, (c) providing an inner ring having a channel adapted to receive the leg of the outer ring and (d) installing the outer ring to the inner ring by inserting the leg into the channel, the insertion forcing the fabric down into the channel and stretching the fabric to the desired tension.

Abstract: The vehicle seat of the invention includes a cushioning material having a ridge surrounding and defining a seating area on the cushioning material and a skin material covering the cushioning material. The skin material and cushioning material are bonded together only within the seating area. The skin material is a laminate including, in succession, a PVC layer, a knitted fabric and a closed-cell synthetic resin foam. A water proof film may be interposed between the cushioning material and the skin material outside of the seating area.

Abstract: An apparatus for facilitating assembling of a covering sheet onto a cushioned padding for a seat, the covering sheet being formed into a three-dimensional shape and having tensioning cords provided therein, the cushioned padding having a central portion, bulged portions formed at both sides of the central portion, and grooves formed in the central portion, the tensioning cords of the covering sheet being to be received in the grooves of the cushioned padding at the time of fastening of the covering sheet to the cushioned padding, and being to be fastened to the cushioned padding, the apparatus including a base table, a supporting member mounted on the base table for receiving and supporting the cushioned padding at the time of the assembling of the covering sheet onto the cushioned padding, hooking arms arranged at both sides of the base table for causing the bulged portions of the cushioned padding on the supporting member to be pulled away from each other and causing the grooves of the cushioned padding to

Abstract: Apparatus and a method for assembling a stretchable cover upon a rigidly backed foam cushion wherein the cushion lateral dimensions vary along its length. The degree of stretching of the cover varies during cushion/cover assembly as controlled by cams and cam followers to permit wrinkle-free covering of backed foam cushions of irregular configuration.

Abstract: A machine and method for securing fabric layers to the core of a fabric panel. The machine includes top rollers and side rollers for stretching the fabric layers along the top surface and side surfaces of the core. Staplers preserve the stretch by stapling the edge of the fabric to the side surfaces. A front stapler and rear stapler are also provided for stapling the fabric to the rear surface and front surface of the core.

Abstract: Apparatus and a method for assembling a stretchable cover upon a rigidly backed foam cushion wherein the cushion lateral dimensions vary along its length. The degree of stretching of the cover varies during cushion/cover assembly as controlled by cams and cam followers to permit wrinkle-free covering of backed foam cushions of irregular configuration.

Abstract: Apparatus and a method for assembling a stretchable cover upon a rigidly backed foam cushion wherein the cushion lateral dimensions vary along its length. The degree of stretching of the cover varies during cushion/cover assembly as controlled by cams and cam followers to permit wrinkle-free covering of backed foam cushions of irregular configuration.

Abstract: A seat assembly machine includes an independently adjustable alignment mechanism. A seat holding mechanism secures a seat frame in place relative to a fabric cover that is supported on another portion of the machine. An independently moveable alignment mechanism includes support posts that are received through openings in the cover and into corresponding receiver portions of the seat frame to properly align those components. After proper alignment is verified, the seat frame is inserted into the cover. The adjustment mechanism is normally biased toward the seat frame holding mechanism and movement of the seat frame holding mechanism overcomes the bias on the alignment mechanism so that the alignment mechanism selectively moves with the seat holder mechanism during an assembly process. The independently positionable alignment mechanism facilitates assembling a variety of seat types using a single machine.

Abstract: A seat assembly machine that uses stanchion rods to install flexible covers on seat cushions characterized by the fact that the stanchion rods are slidably mounted via slides in an axis generally perpendicular to the stuffing or plunging axis such that the stanchion rods more closely follow the contour of the seat cushion. The present invention can be applied to either bottom seat cushion stuffers, back rest stuffers or neck cushion stuffers as desired. In the preferred embodiment the combination of a cam mechanism and spring mechanism controls sliding movement of the stanchion rods. The cam mechanism includes a cam track having an eccentric substantially matched closely to the contour of the intended seat cushion and a follower adapted to follow the eccentric.

Abstract: A machine and method for securing fabric layers to the core of a fabric panel. The machine includes top rollers and side rollers for stretching the fabric layers along the top surface and side surfaces of the core. Staplers preserve the stretch by stapling the edge of the fabric to the side surfaces. A front stapler and rear stapler are also provided for stapling the fabric to the rear surface and front surface of the core.

Abstract: A seat assembling machine commonly known as a skinner or stuffer is adjustable in several axes to allow the machine to be adjusted for different sizes/configurations of seats and seat covers. The machine includes a carriage which is driven towards a padded seat frame. The carriage includes a plurality of generally parallel stanchion rods that can be selectively spaced apart along two different perpendicular axes to receive a selected size of seat cover. The machine inserts a seat cover outside out over padded seat frames. The carriage may selectively rotated, selectively translated forward or horizontally and selectively tilted to better align the stanchion rods with the padded seat frame.

Abstract: A method and apparatus for inserting a supporting insert, such as a set insert (bun) for a vehicle, into a cover, such as a seat cover for a vehicle. The apparatus of the present invention includes a bench upon which a cover holding assembly and a stuffing bracket are provided. The holding assembly comprises four self-adjusting blades which are substantially grouped together at the beginning of the fitting cycle. After an inside-out seat cover's open end is fitted onto the blades, the blades move away from each other into the corners of the cover to expand the cover to its maximum size. The insert is then positioned between the top (closed) end of the covering material and the stuffing bracket. The stuffing bracket then drives the seat insert into the inside-out covering material, gradually turning the material outside-out as the insert is moved forward.

Abstract: The present invention relates to a mechanical device that is used to attach polyester elastomeric fabric hoops to a furniture frame in an efficient and production-worthy manner. These elastomeric hoops are used as the back and seat portions of chairs, double occupant seats, and the like. The invention works by overstretching part of an elastomeric fabric hoop and inserting a furniture frame into the overstretched hoop portion. The fabric hoop is then allowed to reduce its size until it is tight around the frame, thereby eliminating the need for additional attachment means. The device is operated by two air-over-oil pneumatic cylinders, two pneumatic cylinders, and a series of electrical read switches. The device requires only compressed air and 110 volts of alternating electrical current to operate.

Abstract: A method and apparatus for inserting a supporting insert, such as a set insert (bun) for a vehicle, into a cover, such as a seat cover for a vehicle. The apparatus of the present invention includes a bench upon which a cover holding assembly and a stuffing bracket are provided. The holding assembly comprises four self-adjusting blades which are substantially grouped together at the beginning of the fitting cycle. After an inside-out seat cover's open end is fitted onto the blades, the blades move away from each other into the corners of the cover to expand the cover to its maximum size. The insert is then positioned between the top (closed) end of the covering material and the stuffing bracket. The stuffing bracket then drives the seat insert into the inside-out covering material, gradually turning the material outside-out as the insert is moved forward.