Abstract: A foot tension relaxer including a base upon which is mounted three successively narrowing cushion members, with the three cushion members being spanned by a flexible cover member that is attached at its peripheral edges to the base member. The configuration imparted to the flexible cover member by the progressively narrowing juxtaposed cushion members resembles the arch of the human foot. Thus, when a user steps on the flexible cover member, the resilient cushion members react against the weight of the user to gently push upward against the arch to relieve foot tension and pain.

Abstract: An article of seating comprises a shell member and a skin member in contact with the shell member, the skin member being attached to the shell member throughout substantially the entire surface area of mutual contact between the skin member and the shell member.

Abstract: A retainer device for the decorative trim sheets of upholstered cushions, particularly cushions wherein the padding material constitutes thick slabs of molded rubber or synthetic foam, constituting an elongated flexible structure molded in the padding along the base of a groove formed in the upper surface of the padding, and including a series of opposed pairs of resilient claw teeth spaced along the length of the flexible structure, a fold of the trim sheet, or a flexible secondary listing member affixed to the trim sheet, being pressed downwardly into the padding groove to be securely engaged between the pairs of claw teeth. A listing wire or other strand may be included in the listing of the trim sheet, for more secure engagement by the claw teeth, for neater arrangement of the trim sheet, and for greater ease of engagement by the teeth. The retainer also has other uses, all related generally to the attachment of trim sheets to other elements of seating structures.

Abstract: A seating unit having a support structure including a contoured seating surface and a resilient foam covering the seating surface of the support, with the foam having a non-contoured seating surface. The foam includes a plurality of apertures or holes arranged such that upon being deformed by an occupant the seating surface of the foam assumes the shape of the contoured seating surface of the support. The unit is preferably formed of a plurality of individual sub-units of support and foam which are supported in a spaced relationship to form the seating unit.

Abstract: A process for the combination of pneumacel fiber and synthetic elastomeric foam is provided that yields highly desirable, composite cushioning structures. A compressed, resin-bonded pneumacel batt is pre-expanded and combined with a precursor of an elastomeric foam under conditions leading to minor but definite penetration of the batt by the foam to give durably unitary cushioning with the best features of both materials.

Abstract: A method of manufacturing a flexible cushion of foamed plastics material with an integrated cloth cover, comprising forming under vacuum to apply the cloth cover to the inner wall of a mold, and casting a plastics material capable of forming flexible foam, wherein before vacuum forming the cover in the mold the cloth is preformed, and wherein the cloth is maintained adjacent its periphery in a frame which allows the cloth to slide inwards without substantially elongating and undergoes at the level of the frame a peripheral shrinkage while avoiding plait formation, the cloth thus shaped being then fixed at the level of the frame.

Abstract: A metal seat pan is placed inside a rotational casting mold to define part of a rotational casting cavity into which is introduced rotationally castable material for forming a flexible plastic seat cover. A rotational casting operation produces a closed, hollow seat cushion shell defined by the seat pan and the flexible plastic cover. Foaming ingredients are introduced into the hollow shell to form a resilient foamed plastic interior. The resulting seat cushion is monolithic, without seams or joints and has no removable parts or mechanically joined components which will come apart from each other.

Abstract: A method of forming tufted cushion elements comprising the construction of a pattern form with open cavities of various depths and wall inclinations. A piece of facing fabric is spread over the surfaces of the open cavities with its finish face toward the pattern form, and pre-cut oversize cushion elements the unconstrained geometry of which generally conforms to the cavitiesare placed into the open cavities within the facing fabric. A unitary piece of backing fabric is laid over the pattern form and attached to the facing fabric portions exposed between cushion elements along the edges of the cavity partitions, first by an adhesive and next by a sewing operaton. A unitary piece of finished backing fabric is attached on 3 sides to the edges of the backing fabric in order to provide a means of mounting the cushion element on a seat frame.

Abstract: A method for making an article such as a chair seat or the like is disclosed with the method including: attaching a rigid insert to one-half of a mold with an air permeable material extending from between the rigid insert and the mold outward toward the edges of the first half of the mold; inserting a liquid foamable reaction mixture into the cavity of a second half of the mold, placing the two mold halves together with the air permeable material extending from the cavity of the mold to the exterior thereof; allowing the reaction mixture to cure and form a rigid hard structure throughout while expanding around the sides of the rigid insert; and removing the finished article from the mold.

Abstract: An aircraft crew seat cushion having a top cover of high porosity mositure absorbent material over a ventilation layer with a cushioning layer beneath the ventilation layer. The cushioning layer is secured to a shock absorbent layer with an adhesive. The back and sides of the cushion are made of a flame resistant material and together with the top form a cover for the ventilation layer, the cushioning layer and shock absorbent layer.

Abstract: A rocker provides complex rocking motion by virtue of a volume-compressible foam section sandwiched between two substantially rigid upper and lower plate sections. The upper plate, volume-compressible foam, and lower plate sections are secured to form a single integral unit that provides complex relative motion between the upper and lower sections, which motion exhibits pitch and roll characteristics about a vertical axis through the center of gravity of the rocker when occupied.

Abstract: A furniture construction which includes a rigid rectangular frame formed of a plurality of spaced interconnected elements defining the sides of the frame. At least one spring member is provided which extends between and is connected to opposed sides of the frame. The frame and the at least one spring member is formed of one piece of a material which consists essentially of a rigid foamed plastic material.

Abstract: A compartmented bicycle seat padding adapted to be secured to a bicycle seat having depressions formed therein and wherein said padding is enclosed by an outer leather-like exterior and the compartments of said padding receives a formable, stable, dilatant or thixotropic padding material of said padding such as polybutadiene.

Abstract: The invention herein disclosed relates to improved seating units, chairs or sofas, the major component of which comprises a resilient, foam material. A relatively thin base is provided. In final upholstered form the base is hidden from sight during normal use. The seating units have a seat and back portion. Cooperating with the seat and back portion is a rigid rod which is attached to the upholstery which covers the seat and back portions and extends across the width of the seat portion in a slot left unglued between blocks of foam, at the back portion-seat portion juncture. Means, as for example chains, are provided to pull the bar downwardly toward the base and to secure the chains to the base.

Abstract: This invention is a new type of couch or chair using multiple elongated reversible cushions for both the back and seat. The cushion, which may be used any place in the seat or back, has an extension on each end thereof so the back and seat cushions will interlock. The extension also overhangs the front of the couch which forms a part of the couch frame. The couch frame has four legs with the front legs supporting the arm rests and the rear legs supporting the back. A horizontal frame extending between the legs supports the seat cushions. Slats extend horizontally under the cushions for both the seat and back. The frame is formed from wood with saddlebag cushions being draped over the arms of the couch.

Abstract: The structures of the present invention start with a basic hollow tube of any desired outer shape and made of paper, plastic or metal. When paper is used, it is vacuum impregnated with a plastic resin and oven baked to give it rigidity. The tube may also be covered with an ornamental veneer, if desired. The tubes are provided with suitable openings to receive matching counterparts fitting against the openings. Strong, rigid core members of wood, plastic or metal are positioned in the tubular members with the abutting portions of the core members interconnected. The structure is placed in a clamp to hold the parts together in proper position. Polyurethane is then poured into one end, the end is capped, and the structure is rotated to evenly distribute the polyurethane. The urethane sets at room temperature and expands as it sets to internally mold the members into a solid structure. The finished structure can be drilled, machined, or bolted to add features in the conventional manner.

Abstract: An upholstering body for use as the seat, or back, or as a combination seat and back in an article of furniture in which the body has an outer layer of resilient material such as a foamed elastomeric material and a supporting core member in the form of a sheet, or plate, of synthetic material, polyester resin, for example. The sheet is preferably reinforced with glass fibers, which may be in the form of glass cloth. The sheet is adapted for anchoring to a furniture frame in such a manner that the sheet is yieldable in the direction in which a load is normally applied thereto while being generally unyieldable in other directions.

Abstract: A bolster wire assembly is embedded in the resilient foam cushion of a vehicle seat to permit attachment of a seat cover to the foam cushion. The bolster wire assembly includes a wire having a strip of molded plastic mesh attached to and extending continuously therealong. The strip of plastic mesh has a plurality of interstices therein permitting the foam to flow through the plastic mesh during the foaming of the resilient foam cushion so that the strip of plastic mesh is embedded in the foam cushion to thereby anchor the bolster wire in the foam cushion. Conventional fasteners such as hog rings may then be employed to attach a list on the seat cover to the bolster wire.

Abstract: An upholstered seat comprises a supporting structure constituted by rigid elements and embedded entirely in a mass of elastic plastic material which constitutes the upholstering of said seat.

Abstract: A laminated mattress construction having outer layers of relatively soft, virgin foam material and an inner layer or core made of firmer reground, bonded foam. The thickness and firmness of the core are varied in relation to that of the outer layers to achieve a mattress having an overall compression modulus of at least 3. Individually the outer layers are so constructed as to exhibit a 25% ILD range of 10-45 lbs. and the core is so constructed as to exhibit a 25% ILD range of 20-80 lbs. The mattress is further constructed in horizontally juxtaposed sections with one section having firmness characteristics which differ from another section. Finally a removable mattress covering is provided which permits removal of the foam core and separate cleaning or replacement thereof.