A seat includes a seat surface having a periphery and a carrier overmolded onto the seat surface over the periphery. The carrier has a periphery and a frame is overmolded onto the carrier over the carrier periphery. The seat is assembled without fasteners. A method for making the seat includes overmolding a carrier onto a periphery of a seat surface to form a seat surface/carrier assembly, tensioning the seat surface/carrier assembly in a mold and overmolding a frame onto a periphery of the seat surface/carrier assembly.

A seat back for an office chair includes a knit material for extending over a structural frame. The knit material can be formed in a single knitting operation to include cushioning characteristics that vary across different regions of the knit material. The knit material may be a weft knit material having a first layer, a second layer, and a third layer, wherein the third layer is inlayed between the first and second layers and the inlay material is different from at least the first and second layers and provides a degree of cushioning between the first and second layers. The first and second layers are knit according to a predetermined pattern, the predetermined pattern determining crossing lines where the first and second layers cross one another and fix the third layer in position with respect to the first and second layers. The predetermined pattern is differentiated between regions of the back support, such that a first region of the back support has a higher density of crossing lines than a second region of the back support, the first region providing a different degree of cushioning than the second region.

A seat back for an office chair includes a knit material for extending over a structural frame. The knit material can be formed in a single knitting operation to include cushioning characteristics that vary across different regions of the knit material. The knit material may be a weft knit material having a first layer, a second layer, and a third layer, wherein the third layer is inlayed between the first and second layers and the inlay material is different from at least the first and second layers and provides a degree of cushioning between the first and second layers. The first and second layers are knit according to a predetermined pattern, the predetermined pattern determining crossing lines where the first and second layers cross one another and fix the third layer in position with respect to the first and second layers. The predetermined pattern is differentiated between regions of the back support, such that a first region of the back support has a higher density of crossing lines than a second region of the back support, the first region providing a different degree of cushioning than the second region.

A vehicle seat structure, including: a frame member that forms a framework of the vehicle seat; a pad member that is formed of a foam material and is disposed at a front face side of the frame member; and a first rear face member that is integrated with the pad member at a rear face side of the pad member, the first rear face member including: a main body portion that is fixed to the pad member, and an extension portion that extends from the pad member and is fixed to the frame member.

A vehicle seat structure, including: a frame member that forms a framework of the vehicle seat; a pad member that is formed of a foam material and is disposed at a front face side of the frame member; and a first rear face member that is integrated with the pad member at a rear face side of the pad member, the first rear face member including: a main body portion that is fixed to the pad member, and an extension portion that extends from the pad member and is fixed to the frame member.

A chair is provided with a seat support frame which may be comprised of at least two tubes spaced apart by a polymer connector. The seat support frame supports a foam cushion and the frame may be embedded in the foam and may include flexible supports across the support frame also embedded in the foam. A rigid panel has a cavity and the rigid panel is arranged adjacent an outer surface of said foam cushion with at least part of said foam cushion positioned within the cavity, wherein said rigid panel is affixed to said support frame and an inner surface of said rigid panel faces the outer surface of said foam cushion.

A piece of furniture may include a structure having side walls and top walls adjoining the side walls. The piece of furniture may include a blade assembly to cover at least partially the structure, the blade assembly comprising: an envelope comprising a support portion and side panels, the support portion comprising a top layer, a bottom layer, and longitudinal sleeves extending between the top layer and the bottom from about a first one of the side panels to about a second one of the side panels, with the longitudinal sleeves being isolated from each other; and blades inserted in the longitudinal sleeves, wherein the side panels are mounted to the top layer, and wherein the side panels of the blade assembly are secured to the side walls of the structure with the side panels maintaining the bottom layer abutting the top walls.

A method of manufacturing suspension seating includes providing a blank to be used in a suspension member. The blank has a non-visible marker. The method also includes illuminating the non-visible marker with an excitation source. The non-visible marker becomes detectable when illuminated by the excitation source. The method further includes sensing the non-visible marker with a sensor. The sensor is configured to detect the non-visible marker when illuminated by the excitation source. The method also includes determining, by a controller, a characteristic of the blank using the non-visible marker. The controller is in communication with the sensor and configured to receive information related to the non-visible marker from the sensor. The method further includes adjusting the blank to achieve the desired characteristic.

A method of manufacturing suspension seating includes providing a blank to be used in a suspension member. The blank has a non-visible marker. The method also includes illuminating the non-visible marker with an excitation source. The non-visible marker becomes detectable when illuminated by the excitation source. The method further includes sensing the non-visible marker with a sensor. The sensor is configured to detect the non-visible marker when illuminated by the excitation source. The method also includes determining, by a controller, a characteristic of the blank using the non-visible marker. The controller is in communication with the sensor and configured to receive information related to the non-visible marker from the sensor. The method further includes adjusting the blank to achieve the desired characteristic.

In order to solve the issue, during recessed-shape molding for vehicle seats, of requiring a suspension step, more work, members for suspension, and increased cost in a method using suspension, a recessed-shape molding method is provided for vehicle seats having a seat frame, a seat pad covering the seat frame, and a trim cover covering the seat pad. The seat pad has a seat pad groove. An adhesive sheet is sewn on to the rear surface of the trim cover by using outer stitching, the trim cover is put on to the seat pad, then a die is pressed on to the outer stitching from the trim cover surface, the trim cover is adhered to the seat pad groove, and a recessed shape is formed. As a result, a vehicle seat having simplified molding steps and effectively reducing costs can be provided, as well as a vehicle seat molding method used for same.