Abstract: A method for reducing a cushion footprint for long-term storage may include inserting a foam core into a plastic cover, subsequently applying a vacuum to the plastic cover, and, while under the vacuum effect, sealing the plastic cover, and its contents. A device providing the vacuum effect may include a surface having protruding sections connected to non-protruding sections via tapered sections. A cushion may include an at least 20 density high resiliency foam core, and a fabric cover that includes (a) a combination of polyester and spandex and/or lycra, (b) nylon to which a thin water resistant material coating is applied, and/or (c) polyester fabric including raised anti-slip polyvinyl chloride dots, other portions of the polyester fabric at which the dots are not positioned having applied thereto a polyvinyl chloride coating. The device may compress the foam core while housed in a fabric cover, housed in the plastic cover.

Abstract: The present invention discloses a gel mat and a method for manufacturing the same. The purpose thereof is to provide a gel mat which features simple manufacturing process, low cost, ease of use, high reliability, and freedom from possible damage in case of being pierced or depressed with a pressure, and a method for manufacturing the same. The gel mat includes a hermetically sealed bag which is constituted by two layers of a film material, the bag being packed with gel flakes. Said method for manufacturing a gel mat comprises the steps of preparation of material, bag making, monomer solution pouring, heating for solidification, and inspection and packaging in this order. The present invention adopts a gel instead of water, which is conventionally used, for producing a flake gel mat the external surfaces of which are inside a bag; the gel is a colloid obtained by polymerizing the organic matter; approx. 70% of the gel is constituted by water; and thus the gel mat has an extremely good endothermic performance.

Abstract: The present invention relates to a foam pad containing far-infrared and/or ion generating particles and method for producing such foam material. The method for producing the foam pad consists of mixing fine particles of a far-infrared and/or ion emitting stone into the base material prior to further processing such as forming, molding or extruding the material. Alternatively, the fine particles of far-infrared and/or ion generating stone may be mixed with an adhesive and used as a coating on the foam pad. The stone generating far-infrared radiation and/or ions is preferably from the group consisting of tourmaline, granite porphyry, quartz porphyry, zeolite, perlite, serpentine, or mixture thereof.

Abstract: A method of using color or color schemes to simplify the communication to consumers of complex information regarding the combinations and interactions of technically oriented performance attributes that describe the degree of comfort as found in mattresses, mattress foundations, upholstered furniture articles and other articles filled with cushioning materials. Additionally the selected method of using color as a communication tool may be of further benefit in the interaction with consumers by developing strong emotional ties to the consumers purchase decision.

Abstract: A filling device for making a mattress includes a main frame, a feed vessel, a feeding platen, a capping structure, and a power mechanism. The feed vessel includes an open top and a bottom having supplying openings. The feeding platen includes filling containers. Each of the filling containers has an inlet and a gas-supplying unit. The capping structure includes caps. The power mechanism includes a power source and at least one actuating element driven by the power source to actuate the feeding platen to move between a first position in which the inlets of the filling containers are aligned respectively with the supplying openings of the feed vessel, and a second position in which the inlets of the filling container are closed respectively by the caps of the capping structure.

Abstract: A thermoformable, RF-sealable material for use in packaging. The material is produced from a blend including between approximately 5% and 50% by weight of PETG, and between approximately 50% and 95% by weight of PET. A small amount of color concentrate may be added to the blend. The blend may be extruded into sheets and thermoformed to produce packaging material.

Abstract: An apparatus for inserting tuft assemblies through a mattress, with retention disks, comprising a mattress locking structure composed of: two walls, flat and parallel with a space for accommodating the mattress for compression; a first carriage, supported by one of the walls with a first disk feeder and a tuft insertion device; a second carriage, supported by the second wall supporting a second disk feeder; an actuator for the carriages; each one of the feeders for disks comprises a disk magazine that is supported on a respective carriage and contains disks arranged in stack acted upon by a pusher in order to keep a front disk of the stack in a pick-up position; and pick-up elements each with a transfer element, supported by a carriage.

Abstract: An exemplary pocket spring assembly comprises a plurality of elongate fabric tubes disposed adjacent each other. Each fabric tube has a plurality of pockets, with at least some of the pockets of adjacent fabric tubes being welded together at midpoints on the adjacent pocket. Further, a spring is disposed in each of the pockets.

Abstract: A spring unit comprises a continuous coil spring (5) contained within a sleeve (26) of strong, yet flexible, material. The unit is produced by providing a folding attachment device (2) having oppositely inclined spaced walls (13, 14) which converge from a feed end (3) to an outlet end (4), and simultaneously drawing the flexible material and the coil spring through the folding attachment device from the feed end to the outlet end with the spaced walls acting to fold the material over the coil spring and to apply a substantially uniform compressive force to the coil spring. As the material and the spring are drawn through the outlet end (4), overlapping edges of the flexible material are joined together to complete the spring unit.

Abstract: A method of packaging a resiliently compressible article comprises the steps of inserting the article into a tube of deformable material such that excess material is provided at the ends of the tube. A first end of the tube is then sealed closed. Air is then evacuated from the tube through the second end thereby deforming the tube around the article and causing the article to compress. While a vacuum is maintained in the tube, the second end of the tube is sealed closed. A containment sleeve is fitted over the sealed tube to maintain the article in a compressed state. When the article is unpackaged, the containment sleeve is severed and the tube is allowed to expand in a gradual controlled fashion by the bleeding of air back into the tube.

Abstract: A futon mattress is disclosed comprising an outer ticking encasing a foam core disposed between an upper layer and a lower layer of filling. The filling comprises a mixture of down and feathers.

Abstract: A comforter assembly apparatus includes a frame with first and second rolls of fabric associated therewith for supplying an upper sheet and a lower sheet to the apparatus. A pair of sewing machines are mounted on the frame so as to attach the side edges of the upper and lower sheets together to form a continuous fabric assembly. The fabric assembly surrounds, and is pulled through the interior of, a turning ring, so as to continuously invert the fabric assembly into an inside-out condition. A third layer of soft batting may be supplied to the fabric assembly to form a intermediate layer between the upper and lower sheets, by inserting the soft batting layer into the turning ring as the fabric assembly is inverted. In the preferred embodiment, the turning ring is an elongated ring having a leg projecting from each end thereof between a pair of feed rollers.

Abstract: A method and apparatus for applying a cover to a cushion of larger size than the cover by forcing the cushion into a confining chamber which reduces the size of the cushion. The cover is then slid over the cushion. The cushion is then expelled from the chamber taking the cover with it. The cushion expands within the cover as it leaves the confining chamber.

Abstract: A fiber filling system features a picking device for separating clumped fiber, that feeds to an air and fiber circulation chamber. The circulation chamber aerates and fluffs the separated fiber into a fibrous billow, which is then discharged to a stuffing chute. A stuffable article, such as a toy, pillow, or furniture cushion casing is attached to the chute and is filled with the fibrous billow in a metered amount.

Abstract: A feather quilt comprising upper and lower cloth layers, a multiplicity of rectangular spaces arrayed in regular rows and files in the interspace between the upper and the lower layer, and down placed to fill up the rectangular spaces is manufactured by sewing ribbon-like partition pieces to the inner sides of the upper and lower layers along the individual boundaries of the rectangular spaces running in the longitudinal (or lateral) direction and T-shaped partition pieces to the aforementioned inner sides along the individual boundaries of the rectangular spaces running in the lateral (or longitudinal) direction, sewing together the corresponding ribbonlike partition pieces fastened to the upper and lower layers, similarly sewing the T-shaped partition pieces together with the exception of the openings formed of the projecting portions thereof, and sequentially filling with down the rectangular spaces formed between the upper and lower layers by the use of a down injection tube inserted through the openings

Abstract: A method of stuffing an aerated expanded flexible filler into a snug fitting cover, wherein air is evacuated from the filler while resting upon a support so as to shrink the filler and permit rapid application of the cover thereto. The apparatus includes a cantilevered chambered support with multiple openings in its filler supporting surface and selectively operable means for withdrawing air from the chamber and an air impervious sheet draped over the filler and the support.

Abstract: An apparatus for stuffing cushions, mattresses, and the like. The apparatus includes a cantilevered hollow support with multiple perforations in its upper wall and selectively operable means for evacuating air from the hollow support. Cushion stuffing material is placed on the support and covered with an air impervious film advanced from a supply member carried by the apparatus and cut by a cutter adjustably mounted on the apparatus. The film closes exposed perforations of the support which are not covered by the stuffing material. The apparatus is used to evacuate the air from the stuffing material, thereby shrinking the material to allow the rapid application of a cover over the stuffing and support, followed by withdrawal of the cover and contained stuffing from the support.

Abstract: A method of stuffing an aerated expanded flexible filler into a snug fitting cover, wherein air is evacuated from the filler while resting upon a support so as to shrink the filler and permit rapid application of the cover thereto. The apparatus includes a cantilevered chambered support with multiple openings in its filler supporting surface and selectively operable means for withdrawing air from the chamber.

Abstract: A machine for filling a cloth bag with cloth filling material having a series of elongated fingers and a hollow spout mounted on a rectangular frame in registry with one another for movement relative to one another along the frame such that the fingers advance into and retract out of the passageway. A cloth filler material is spread upon the fingers and the bag to be filled is draped over the spout so that the inside bottom of the bag is facing the fingers. An air operated double acting cylinder is actuated to drive an endless cable which cable may either be operatively connected to a roller assembly connected to a rear end portion of the fingers or to the spout depending upon whether it is desired to move the fingers into and out of the spout or move the spout along and over the fingers. Movement of the fingers into the spout or vice versa forces the bottom of the bag through the spout and extends the bag over the fingers and the filler material spread thereon.

Abstract: Resilient articles, such as, mattresses and cushions of varying yield resistance to accommodate the weight variation of the body and/or to provide edge support are produced by tailoring tensile forces within the article. Tensile force variation may be accomplished in articles of uniform density by slotting to separate adjacent regions in at least one direction. Tailoring is accomplished by variation in slot depth and/or spacing.

Abstract: A method of packaging a resiliently compressible article comprises the steps of inserting the article into a tube of deformable material such that excess material is provided at the ends of the tube. A first end of the tube is then sealed closed. Air is then evacuated from the tube through the second end thereby deforming the tube around the article and causing the article to compress. While a vacuum is maintained in the tube, the second end of the tube is sealed closed. A containment sleeve is fitted over the sealed tube to maintain the article in a compressed state. When the article is unpackaged, the containment sleeve is severed and the tube is allowed to expand in a gradual controlled fashion by the bleeding of air back into the tube.