A fiber cushion body comprises a first portion in which fibers have a preferential orientation along a first direction and at least a second portion having a fiber orientation and/or density different from the first portion. The fiber cushion body is processed using laser radiation to form a laser cut or laser weld.

A fiber cushion body comprises a first portion in which fibers have a preferential orientation along a first direction and at least a second portion having a fiber orientation and/or density different from the first portion. The fiber cushion body is processed using laser radiation to form a laser cut or laser weld.

A seating unit component assembly comprises a support component that includes a first surface adapted to abut a seated user, a second surface opposite the first surface, a first end surface, a second end surface opposite the first end surface, and a pair of side surfaces extending between the first and second end surfaces, and a cover having a plurality of sides that cooperate to form an interior space that receives the support component therein, wherein the cover includes a first portion comprising a non-fabric substantially flexible thermoplastic material covering at least a portion of at least one of the side surfaces of the support component, a second portion comprising a fabric covering at least a portion of the first surface and at least a portion of the first end surface of the support component, and a third portion comprising a substantially rigid overlay covering at least a portion of the second end surface and at least a portion of the second surface.

A seating unit component assembly comprises a support component that includes a first surface adapted to abut a seated user, a second surface opposite the first surface, a first end surface, a second end surface opposite the first end surface, and a pair of side surfaces extending between the first and second end surfaces, and a cover having a plurality of sides that cooperate to form an interior space that receives the support component therein, wherein the cover includes a first portion comprising a non-fabric substantially flexible thermoplastic material covering at least a portion of at least one of the side surfaces of the support component, a second portion comprising a fabric covering at least a portion of the first surface and at least a portion of the first end surface of the support component, and a third portion comprising a substantially rigid overlay covering at least a portion of the second end surface and at least a portion of the second surface.

A method for producing a seat core material that has a foamed molded substrate and a frame member embedded in a periphery thereof, which includes, as step (a), heating thermoplastic resin expanded beads in a mold cavity, in which the frame member has been disposed, to fusion-bond the expanded beads to each other and to obtain the foamed molded substrate with the frame member being embedded in the periphery thereof; and, as step (b), simultaneously with step (a) or after step (a), forming a void cavity S, S in the foamed molded substrate at a position along and adjacent to the frame member. The void cavity S, S has a size and shape that allows a relative displacement between the frame member and the foamed molded substrate when the foamed molded substrate shrinks after step (b).

A method for producing a seat core material that has a foamed molded substrate and a frame member embedded in a periphery thereof, which includes, as step (a), heating thermoplastic resin expanded beads in a mold cavity, in which the frame member has been disposed, to fusion-bond the expanded beads to each other and to obtain the foamed molded substrate with the frame member being embedded in the periphery thereof; and, as step (b), simultaneously with step (a) or after step (a), forming a void cavity S, S in the foamed molded substrate at a position along and adjacent to the frame member. The void cavity S, S has a size and shape that allows a relative displacement between the frame member and the foamed molded substrate when the foamed molded substrate shrinks after step (b).

Various embodiments relates to a chair cover for covering at least a part of a chair, the chair cover comprising: at least one first panel formed of or from a first fabric, and configured to cover at least one middle section having a centreline of the at least the part of the chair; and a plurality of second panels formed of or from a second fabric different from the first fabric and joined together with the at least one first panel, wherein the plurality of second panels are configured to cover edges of the at least the part of the chair surrounding the at least one middle section, and wherein the plurality of second panels are configured to be stretched more than the at least one first panel such that the chair cover fits snugly around the edges of the at least the part of the chair.

Various embodiments relates to a chair cover for covering at least a part of a chair, the chair cover comprising: at least one first panel formed of or from a first fabric, and configured to cover at least one middle section having a centreline of the at least the part of the chair; and a plurality of second panels formed of or from a second fabric different from the first fabric and joined together with the at least one first panel, wherein the plurality of second panels are configured to cover edges of the at least the part of the chair surrounding the at least one middle section, and wherein the plurality of second panels are configured to be stretched more than the at least one first panel such that the chair cover fits snugly around the edges of the at least the part of the chair.

Cushions, methods, and manufacturing systems for making the same are disclosed. The cushions may be foamless such as being made from a body of entangled and/or intertwined polymeric strands. The manufacturing systems may include a die such as die bars having a plurality of orifices that cooperate with a plurality of receptacles and actuators for discharging a plurality of fasteners from the receptacles, through the die into the cushions. In a refinement, the die may be heated such that a skinned over membrane is created in the cushion to retain the plurality of fasteners. A trim cover may cooperate with the plurality of fasteners such that it is attached to the cushion.

Cushions, methods, and manufacturing systems for making the same are disclosed. The cushions may be foamless such as being made from a body of entangled and/or intertwined polymeric strands. The manufacturing systems may include a die such as die bars having a plurality of orifices that cooperate with a plurality of receptacles and actuators for discharging a plurality of fasteners from the receptacles, through the die into the cushions. In a refinement, the die may be heated such that a skinned over membrane is created in the cushion to retain the plurality of fasteners. A trim cover may cooperate with the plurality of fasteners such that it is attached to the cushion.