A cushion having a fibrous foam architecture. The cushion has a trim cover and a number of fibrous layers attached to the trim cover. One or more structural properties of a fibrous layer can be controlled to differ from that of other layers.

A comfortable, well-designed vehicle seat (1) is provided by giving an outstanding, three-dimensional appearance to the surface layer of the vehicle seat so that a new design is achieved and that softness is improved. The vehicle seat has a seat cushion (2) serving as the sitting surface of the seat, a seatback (3) serving as the backrest of the seat, and a headrest (4) protecting the head and neck of an occupant. The surface of at least one of the seat cushion and the seatback is provided with a cover formed of a cloth including an upholstery material (6), a cushion material (8), and a heat-shrinkable material (9). The cover is stitched so that a plurality of bumps and dips are formed on the surface thereof.

An assembly is provided with a unitary mesh of expanded thermoplastic resin strands with a cavity formed therein. A trim component or a support member is oriented at least partially within the cavity. A weld is formed at least partially along the mesh adjacent to the cavity to retain the trim component or the support member within the cavity.

An assembly is provided with a unitary mesh of expanded thermoplastic resin strands with a cavity formed therein. A trim component or a support member is oriented at least partially within the cavity. A weld is formed at least partially along the mesh adjacent to the cavity to retain the trim component or the support member within the cavity.

A seat cover made of leather for a vehicle seat is disclosed. The seat cover has two or more blank parts as first blank parts, wherein the first blank parts are joined to each other on at least one joining edge. At least one first blank part has a width that is at least equal to the width of a following blank part of a follower and the first blank part has a length that is at least equal to the length of the following blank part of the follower.

An improved conveyance seat is configured by an overlapping part of a skin material being hung in a recessed portion formed at a boundary position between a support portion and an intersecting portion of the cushion material when the cushion material divided into pieces is covered by the skin material having the overlapping part configured by two skin material fragments overlapping each other. The skin material fragments inserted into the recessed portion have first and second parts satisfying the following conditions: (1) The first parts are welded to contact each other on a back side of the recessed portion behind an opening of the recessed portion and parts of the first parts are crushed, (2) The second parts adjacent to the first parts and closer to the opening of the recessed portion than the first parts are separated from each other.

According to one or more embodiments, a vehicle seat assembly includes a cushion and a leather trim cover assembly disposed over the cushion. The leather trim cover assembly includes a leather upper layer and a foundation layer secured to the leather upper layer at radio-frequency weld points. The radio-frequency weld points define at least one design boundary adjacent a raised portion of a protruding design in the leather trim cover assembly.

A method produces an element (3), in particular a vehicle seat, having a seamless cover (2). The seamless cover (2) is optionally provided with a lamination (1). A molding (1.2) is applied and fastened to a surface side (1.1) of the lamination (1) facing away from the cover (2) or to a surface side (2.2) of the cover (2) that is not visible. The fastened molding (1.2) is connected to the cover (2) by bonding.

A body of extruded polymer fibers formed and welded together in a three-dimensional shape with a fastener comprising a stake inserted into the body. The stake comprises a head that secures the fastener to the body. The body comprises extruded polymer filaments randomly oriented and bonded together to form a three-dimensional mesh structure. The polymer stake extends from a plate through a first side toward a second side of the body to a location on the surface of the body or a location within the body. A portion of the filaments is disposed between the first side of the body and the head. A method of attaching the fastener to the body comprises inserting the stake, forming the head, and attaching the head to the body.

A seat support is provided with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other, and each of the plurality of stacked layers has a generally uniform thickness.