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.

An office-type chair includes a back support having a support frame, front and rear shells, a cushion and a cover. The perimeter edge of the cover wraps around the side of the cushion and the front shell and is inserted between the front and rear shells to form a finished edge for the cover. The front shell may include a central flex section, and a lumbar pad may be positioned between the front shell and the rear shell and adjacent to the central flex section. One or more lumbar enhancement ribs on the front shell may augment the pressure distribution of the lumbar pad as it is vertically adjusted.

An office-type chair includes a back support having a support frame, front and rear shells, a cushion and a cover. The perimeter edge of the cover wraps around the side of the cushion and the front shell and is inserted between the front and rear shells to form a finished edge for the cover. The front shell may include a central flex section, and a lumbar pad may be positioned between the front shell and the rear shell and adjacent to the central flex section. One or more lumbar enhancement ribs on the front shell may augment the pressure distribution of the lumbar pad as it is vertically adjusted.

A modular sofa system, where each module includes a generally square frame and one or more arm or back elements; and where the feet of the arm or back elements are constructed to support the generally square frame. The separate modules can be joined together to form a sofa of the desired configuration.

A modular sofa system, where each module includes a generally square frame and one or more arm or back elements; and where the feet of the arm or back elements are constructed to support the generally square frame. The separate modules can be joined together to form a sofa of the desired configuration.

A cushion assembly for supporting a sitting or reclining person includes a cushion formed with a cushion aperture. The person may suspend a part of their body within the void space of the cushion aperture to avoid contact pressure between the cushion assembly and the suspended body part. An optional cushion insert may be positioned in the cushion aperture. The cushion insert is formed with a bilobate insert aperture and an insert ridge projecting into the insert aperture has a first insert aperture lobe extending away from a first side of the insert ridge and a second insert aperture lobe extending away from a second side of the insert ridge. The cushion insert modifies a size and perimeter shape of the void space in the cushion aperture.

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.

There is disclosed an improved seat element having a seating surface element that incorporates a plurality of peak portions and a plurality of valley portions. Preferably, the plurality of peak portions and the plurality of valley portions is incorporated in an outermost surface of the seating surface element. The term outermost surface is intended to include an area of the seating surface element for contact by and/or support of an occupant of the seat element and does not include, for example, grooves or trenches in which there is disposed a component for attachment of a trim cover. A process and a mold for production of such a seat element are also described.

There is disclosed an improved seat element having a seating surface element that incorporates a plurality of peak portions and a plurality of valley portions. Preferably, the plurality of peak portions and the plurality of valley portions is incorporated in an outermost surface of the seating surface element. The term outermost surface is intended to include an area of the seating surface element for contact by and/or support of an occupant of the seat element and does not include, for example, grooves or trenches in which there is disposed a component for attachment of a trim cover. A process and a mold for production of such a seat element are also described.

Furniture with a heated seat consists of a fixed furniture frame having a seating surface to accommodate one or more cushions. One or more removable cushions are positioned on the seating surface. Each removable cushion includes a foam body. An electric heating pad is supported by the foam body. A cushion cover is provided that overlies the foam body. An umbilical power cord is electrically coupled to the heating pad. The umbilical power cord extends from the foam body through an opening in the cushion cover and connects with an electrical connector of a power transformer module on the furniture frame. Power is supplied by the power transformer module to the heating pad when the activation switch of the power transformer module is in the on position.