According to the disclosure, a seat pad 2 includes a bag-contained pad part 250 including a foam body 240 and a bag body 230 arranged inside the foam body 240.

According to the disclosure, a seat pad 2 includes a bag-contained pad part 250 including a foam body 240 and a bag body 230 arranged inside the foam body 240.

A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Any superimposed central portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).

A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Any superimposed central portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).

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.

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.

In described examples, a cushioning unit assembler includes first, second, third, and fourth rows of welding heads, a transport, and a feed module. The welding heads have a welding position and a retracted position. A main axis of the welding heads is oriented in a first dimension while in the welding position. The transport is disposed above the rows of welding heads. The transport has a main axis oriented in a second dimension perpendicular to the first dimension. The feed module includes a pocketed spring intake and a pocketed spring outflow. The transport is mechanically coupled to enable the feed module to move in the second dimension along a scope of movement. An exit aperture of the outflow vertically aligns with welding heads of the first row that are in the welding position, and vertically aligns with welding heads of the second row that are in the welding position.

A gel layer, comprising a first gel lattice having a first geometric shape. The first geometric shape has a first gel lattice height; a first gel lattice width; and a first gel lattice length. The first gel lattice comprises a plurality of first gel segments, wherein the first gel segments define a plurality of first gaps. The first gel lattice has a first firmness.

A spring mattress comprises a plurality of interconnected coil springs enclosed in casings, the springs having a first and a second end, wherein for at least one of the springs, casing portions arranged at the first and second ends of the spring are connected to each other through the spring by a joint. The joined casing portions comprise openings through the spring. Pieces of foam material are arranged in the openings, so that a first portion of each piece of foam material extends towards the first end of the spring and a second portion of each piece of foam material extends towards the second end of the spring. An apparatus and method for manufacturing such a mattress are also disclosed.

A spring mattress comprises a plurality of interconnected coil springs enclosed in casings, the springs having a first and a second end, wherein for at least one of the springs, casing portions arranged at the first and second ends of the spring are connected to each other through the spring by a joint. The joined casing portions comprise openings through the spring. Pieces of foam material are arranged in the openings, so that a first portion of each piece of foam material extends towards the first end of the spring and a second portion of each piece of foam material extends towards the second end of the spring. An apparatus and method for manufacturing such a mattress are also disclosed.