A method of manufacturing a folding mat includes: suctioning a first film onto a lower mold, in which a downwardly concave slit groove is formed at one end of a cavity such that a portion of the first film forms a unit fold part; inserting the unit filler over the first film; disposing a second film on an upper side of the lower mold to cover the unit filler; attaching the edge parts of the first and the second films together by using an upper mold mating with the lower mold; trimming an attachment part of the unit mats thus fabricated; fusing the unit fold part of the unit mat with the unit fold part of an adjacent unit mat; and fusing the attachment part of one of the two unit mats thus connected with the attachment part or the unit fold part of another unit mat.

To produce a seat cushion body, at least one yarn is cut to produce a fiber material. The fiber material is transported from a cutter system which cuts the at least one yarn to a mold.

A method for forming cushions including the following four steps: (1) a compression step in which the structure (2) is compressed in a mold (3); (2) a thermal softening step in which the structure (2) is thermally softened by means of a heating medium; (3) a curing step in which the structure (2) directly undergoes forced cooling in a cooling medium, and is then cured; and (4) a mold release step in which the structure (2) is released from the mold (3).

A method for manufacturing a vehicle seat element comprising the following steps: a. providing an armature of the seat element, b. providing a net and a frame, at least one portion of the net being surrounded by the frame and fastened to the frame, c. fastening the frame and/or the net to the armature, d. providing a padding comprising a 3D tangling of continuous thermoplastic fibers arranged irregularly forming loops welded together, and e. fastening the padding onto the net and/or onto the frame.

Implementations described and claimed herein include a cushioning material layer and method for manufacturing a cushioning material layer, which allows for maximum comfort through the compression and shock cycle. Specifically, a cushioning material layer comprises void cells formed in an array, which comprise multiple outwardly facing curvatures, with varying radius measurements. Stiffness in the void cells can vary by varying the radiuses. The outwardly facing curvatures prevent buckling and provide support for high impact by absorbing energy.

This disclosure is directed to the manufacturing of bicycle saddles. For instance, in some examples, a process to manufacture a bicycle saddle provides a central through channel as well as a hull with a through hole, a polyurethane layer as a padding element, and a liner adapted to cover the polyurethane layer. The process allows for the manufacturing of bicycle saddles that have various significant advantages over prior art bicycle saddles, including advantages from both an aesthetic and functional point of view of a user.

Method for producing a cushion with a casing made of an airtight casing material and a flexible, polydirectionally air-permeable filling body which is arranged in the casing and which is materially connected to the casing. The method includes at least the following steps: coating a first mold cavity of a molding tool with a curable, flowable and/or sprayable plastic material to form a first casing shell, coating a second mold cavity of the molding tool with the curable, flowable and/or sprayable plastic material to form a second casing shell, inserting a pre-produced filling body into the first casing shell located in the first mold cavity, and joining together of the first and second casing shells located in the first mold cavity and in the second mold cavity before the plastic material cures or fully reacts.

The invention relates to a method for producing a cushion for an orthopedic device, the cushion having a first component, which comprises a first film layer and a second film layer, and a second component that are joined with each other in such a way that there is at least one fluid-filled volume between the first component and the second component, the method comprising the following steps: inserting the first film layer, which has at least one opening, and the second film layer into a tool, which has an upper mold and a lower mold; applying a differential pressure to at least one of the film layers, so that the at least one film layer moves at least in sections towards the upper mold or the lower mold, thereby creating a distance between the two films; joining the two film layers along at least one connection line.

A method for manufacturing a vehicle seat component includes a first step of integrating a cushion member and an upholstery member together during molding of the cushion member, and a second step of forming a flow passage through which air passes from a back surface of the cushion member toward the upholstery member.

A support comfort cushion is disclosed comprising a plurality of gel springs absorbs, a plurality of interlocking support members, and a base cushion, all of which serve to redistribute directional force as applied, proportionate to the weight and anatomy of an animal or human, i.e. those areas of anatomy most susceptible to pressure points, e.g. elbows, paws, neck, shoulders, back, hip joints. The gel springs contain bellows and adjacent gel spring junctions which act together providing transitional resistive slippage to dynamic influence of weight and movement, all the while providing counter-pressure, suspension.