A method of manufacturing a product, dispenses, through a tool with an aperture sized to match an overall perimeter of a product, a molten thermoplastic resin. The tool generates a plurality of strands through the tool aperture while maintaining the plurality of strands within the overall perimeter of the product. The strands are buckled by resisting a flow of the plurality of strands. The buckled strands intersect as a unitary non-woven body in a shape of the overall perimeter of the product.

A manufacturing method of a seating device includes manufacturing an outer skin; manufacturing a core member via a foaming process; wrapping the core member in the outer skin, coupling a mounting plate at a bottom surface of the core member; and selectively coupling a mounting structure to the mounting plate to form the seating device. The outer skin is constructed to have a top skin layer adhered on a top surface of the core member, a side skin layer adhered on a side surface of the core member, and a bottom skin layer adhered on a bottom surface of the core member. Particularly, the top skin layer of the outer skin is adhered on the top surface of the core member edge-to-edge to initially align and retain the outer skin on the core member.

A filling-body manufacturing method is a method of manufacturing a filling body 8 that fills a hole part 74 formed at a seat body 7 and at least part of which is bonded to the seat body 7 in a passenger-seat cushion member including the seat body 7 and the filling body, the filling body 8 being a porous structural body 1S made of flexible resin or rubber, the filling-body manufacturing method including a shaping step of shaping the filling body 8 by using a 3D printer.

A method of thermal compacting of an airbag cushion is described where rapid heating is conducted by a microwave beam directed at a mold through a radiation transparent wall without materially heating the mold itself.

The present invention is a system and method for manufacturing a framework for a padded cushion in the shape of a kneeler pad, wherein the framework is created using a thermoforming process to make rigid and plastic top and bottom shells that are then coupled together to form a framework to which upholstery is added to thereby form a padded kneeling cushion, wherein a fabric tightening system is also installed in the framework that enables the upholstery to be stretched tighter over the framework in order to tighten the upholstery around the cushion as the upholstery loses its shape and stretches over time, and wherein a system is provided to extend a length of the kneeler pads through the addition of expansion segments in the framework.

The present invention provides a CFT pre-forming insert injection molded seat back frame. The CFT pre-forming insert injection molded seat back frame comprises: a pair of frame parts which are coupled to face each other and have fiber reinforced plastic formed therein; and reinforcement parts which are formed on regions that the pair of frames respectively face, and are coupled to each other in multiple locations.

A seating arrangement includes a base member, and an integrally formed support member coupled to the base member and supporting a seat moveable from an upright position to a reclined position, wherein a portion of the support member is bendable as the seat moves from the upright position to the reclined position such that a first side of the support member is put in tension and a second side generally opposite the first side is put in compression, and wherein the first side includes a tensile substrate so that the first side has as higher modulus of elasticity than the second side.

A cushion for a piece of furniture or a pillow includes a cushion core and an exterior cover at least partially surrounding the cushion core. The cushion core comprises a cushion wrap surrounding a filler, which may be foam or fiber or down or any known filler. The cushion wrap is at least partially made of fabric having a raised surface pattern to increase friction between the cushion core and the exterior cover for holding the cushion core in a desired orientation inside the exterior cover.

A seating arrangement includes a base member, and an integrally formed support member coupled to the base member and supporting a seat moveable from an upright position to a reclined position, wherein a first portion of the support member positioned rearwardly of the base member is bendable such that an upper layer of the first portion is put in tension, and wherein a second portion of the support member positioned forwardly of the base member is bendable such that a lower layer of the second portion is put in tension, wherein the upper layer of the first portion and the lower layer of the second portion are reinforced with at least one tensile substrate.

According to the present invention, in a plan view of a seat surface (10a), a plane area of a part surrounded by an inner edge (17a) of a rear part (17) in a left-right direction (X) and a contour (L) is larger than a plane area of a part sandwiched by an inner edge (18a) of a front part (18) in the left-right direction (X) and the contour (L) in the left-right direction (X). In addition, a part of a pair of left and right second synthetic resin materials forming a lower part having a maximum gap therebetween in the left-right direction (X) is positioned in a thigh rest part (14) and a part having a minimum gap is positioned in a hip rest part (15), and a maximum value (W1) of the gap between the pair of left and right second synthetic resin materials forming the lower part in the left-right direction (X) is two times or more a minimum value (W2) of the gap in the left-right direction (X).