An improved chair seat design is disclosed comprising a foam cushioning unit having top, middle, and bottom layers of foam secured together into a single unit. The bottom layer of foam includes a recess or slot sized to accommodate a void cell cushioning layer. The void cell cushioning layer is inserted into the recess/slot of the foam cushioning unit. Preferably, the void cell cushioning layer comprises an upper layer having an array of smaller cells with peaks pointing downwardly and pockets facing upwardly into the foam cushioning unit, and a lower layer having larger cells with peaks pointing upwardly and pockets facing downwardly relative to the foam cushioning unit. The foam cushioning unit with void cell cushioning layer inserted is then preferably attached to a contoured seat pan to form an improved office chair seat.

An improved chair seat design is disclosed comprising a foam cushioning unit having top, middle, and bottom layers of foam secured together into a single unit. The bottom layer of foam includes a recess or slot sized to accommodate a void cell cushioning layer. The void cell cushioning layer is inserted into the recess/slot of the foam cushioning unit. Preferably, the void cell cushioning layer comprises an upper layer having an array of smaller cells with peaks pointing downwardly and pockets facing upwardly into the foam cushioning unit, and a lower layer having larger cells with peaks pointing upwardly and pockets facing downwardly relative to the foam cushioning unit. The foam cushioning unit with void cell cushioning layer inserted is then preferably attached to a contoured seat pan to form an improved office chair seat.

An improved chair seat design is disclosed comprising a foam cushioning unit having top, middle, and bottom layers of foam secured together into a single unit. The bottom layer of foam includes a recess or slot sized to accommodate a void cell cushioning layer. The void cell cushioning layer is inserted into the recess: slot of the foam cushioning unit. Preferably, the void cell cushioning layer comprises an upper layer having an array of smaller cells with peaks pointing downwardly and pockets facing upwardly into the foam cushioning unit, and a lower layer having larger cells with peaks pointing upwardly and pockets facing downwardly relative to the foam cushioning unit. The foam cushioning unit with void cell cushioning layer inserted is then preferably attached to a contoured seat pan to form an improved office chair seat.

An improved chair seat design is disclosed comprising a foam cushioning unit having top, middle, and bottom layers of foam secured together into a single unit. The bottom layer of foam includes a recess or slot sized to accommodate a void cell cushioning layer. The void cell cushioning layer is inserted into the recess: slot of the foam cushioning unit. Preferably, the void cell cushioning layer comprises an upper layer having an array of smaller cells with peaks pointing downwardly and pockets facing upwardly into the foam cushioning unit, and a lower layer having larger cells with peaks pointing upwardly and pockets facing downwardly relative to the foam cushioning unit. The foam cushioning unit with void cell cushioning layer inserted is then preferably attached to a contoured seat pan to form an improved office chair seat.

A body support structure comprising one or more gel layers, such as structures comprising a plurality of ridges and a plurality of valleys. Methods of forming the gel layers and body support structures comprising the gel layers. Systems for manufacturing body support structures comprising the gel layers.

A body support structure comprising one or more gel layers, such as structures comprising a plurality of ridges and a plurality of valleys. Methods of forming the gel layers and body support structures comprising the gel layers. Systems for manufacturing body support structures comprising the gel layers.

A body support structure comprising a gel layer comprising at least a first gel lattice, wherein the first gel lattice comprises a plurality of first gel segments, wherein the plurality of first gel segments defines a plurality of first gaps; and a viscoelastic foam layer; wherein the gel layer is directly laminated to the viscoelastic foam layer. Methods of forming the gel layers and body support structures comprising the gel layers. Systems for manufacturing body support structures comprising the gel layers.

In order to manufacture an innerspring unit (31) comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body (30) comprising a plurality of first strings (14) of pocketed springs is provided. In a subsequent second step, at least one second string (13c, 13d) of pocketed springs is attached to a lateral surface of the innerspring main body (30), so that the at least one second string (13c, 13d) of pocketed springs extends in a longitudinal direction of the innerspring main body (30). The springs (13) of the at least one second string (13c, 13d) of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body (30). The at least one second string (13c, 13d) of pocketed springs forms together with the innerspring main body (30) the innerspring unit (31).

In order to manufacture an innerspring unit (31) comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body (30) comprising a plurality of first strings (14) of pocketed springs is provided. In a subsequent second step, at least one second string (13c, 13d) of pocketed springs is attached to a lateral surface of the innerspring main body (30), so that the at least one second string (13c, 13d) of pocketed springs extends in a longitudinal direction of the innerspring main body (30). The springs (13) of the at least one second string (13c, 13d) of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body (30). The at least one second string (13c, 13d) of pocketed springs forms together with the innerspring main body (30) the innerspring unit (31).

An upholstered chair, recliner, or sofa with a frame including a pair blowmolded hollow arm rest forms, wherein frame members extend between the forms. Further components may be blowmolded such as a backrest. The arm rest forms and backrest may be reinforced with metal plates and assembled into a recliner. The connections to the arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust. Upholstery sacks are easily attached to the frame.