A chair back assembly includes a back frame having a front surface and a rear surface and including a laterally extending cross member having opposite end portions, a back shell including a front surface, a rear surface positioned in front of the front surface of the back frame, a pair of laterally spaced side portions defining an opening therebetween, and a top portion extending laterally between and connected to the side portions, wherein the side portions are exclusively connected to the cross member at opposite ends of the cross member, wherein the connection between the side portions of the back shell and the end portions of the cross member are the only connections between the side portions of the back shell and the back frame, and a cover extending across the opening and connected to the side portions and the top portion of the back shell.

A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies of fabric. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least cushion pad is positioned in each outer pocket. The cushion pad may be individually pocketed. An upper end of each transverse seam may be below an upper surface of the string to partially separate adjacent outer pockets within a string.

A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies of fabric. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least cushion pad is positioned in each outer pocket. The cushion pad may be individually pocketed. An upper end of each transverse seam may be below an upper surface of the string to partially separate adjacent outer pockets within a string.

A method is provided for enhancing comfort of a seat with a hip/thigh support and a back support. The method includes providing a seating pad assembly with a foam cushion made at least partly of a viscoelastic foam and having a cover formed from a dimensionally stable non-stretch material. An upper area of the seating pad assembly is attached to an upper area of the seat back. Pelvic and upper back areas of a person sitting on the seat deform the viscoelastic foam sufficiently to provide a comfortable support and to define anchors for the seating pad assembly. The non-stretch cover extends between those anchors for effectively supporting and cradling the lumbar back area of the person in the seat above and forward of the corner between the seat back and the hip/thigh support.

A chair assembly includes a four-bar arrangement that includes a lower end and an upper end where the upper end is adjustable between a raised position and a lowered position, and an arm rest assembly adapted to support the arm of a seated user thereon and supported on an upper end of the four-bar arrangement, wherein the lower end of the four-bar arrangement is pivotably supported from an arm support structure for pivotable movement about an arm pivot axis, such that the upper end of the four-bar arrangement is movable between a first position and second position located laterally outward from the first position, and wherein the arm pivot axis is angularly offset from a vertical axis.

A chair having a first frame portion with a backrest support and a rear leg portion at least part of the backrest support and the leg portion being formed from a single piece. A second frame portion has a seat support and a front leg portion extending in a direction transverse to the seat support, the seat support in a fixed position relative to the backrest support. The backrest support molded thereover in foam, the backrest support being substantially peripherally located around the foam of the backrest and the backrest being provided free from rigid supports extending across a middle portion of the backrest. The seat support molded thereover in foam, the seat support being substantially peripherally located around the foam of the seat and the seat being provided free from rigid supports extending across a middle portion of the seat.

A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.

A pocketed spring comfort layer for a bedding or seating product has pockets characterized by the individual mini coil springs of the comfort layer being pocketed with between at least one cushion assembly and a sheet of polypropylene fabric. Each cushion assembly includes at least one foam layer. A segmented seam joins the cushion assembly and the sheet of polypropylene fabric around each of the mini coil springs of the pocketed spring comfort layer. The method of making the pocketed spring comfort layer includes compressing the mini coil springs and creating pockets with a welding horn and an anvil.

A system may include an access engine and a foam part generation engine. The access engine may be configured to access a computer-aided design (CAD) seat surface that represents a seat surface of a seat design and access seat parameters for the seat design. The foam part generation engine may be configured to construct a CAD foam part for the seat design based on the CAD seat surface and the seat parameters.

A non-slip cushion includes a layer of a honeycomb gel for diminishing high pressure areas to reduce pressure ulcers.