A synthetic resin skin material composite, including: a urethane resin skin material including a urethane resin skin layer provided at one surface of a substrate; and a cushion layer that is placed at a surface on an opposite side of the substrate from the surface of the urethane resin skin material at which the urethane resin skin layer is provided; in which the urethane resin skin material has recesses at a side of the urethane resin skin layer, and each of the recesses has a depth in a thickness direction of the synthetic resin skin material composite, such that the recesses extend from the urethane resin skin layer into the cushion layer beyond an interface between the urethane resin skin material and the cushion layer that is present in a region without a recess, as well as a method of producing a synthetic resin skin material composite.

A synthetic resin skin material composite, including: a urethane resin skin material including a urethane resin skin layer provided at one surface of a substrate; and a cushion layer that is placed at a surface on an opposite side of the substrate from the surface of the urethane resin skin material at which the urethane resin skin layer is provided; in which the urethane resin skin material has recesses at a side of the urethane resin skin layer, and each of the recesses has a depth in a thickness direction of the synthetic resin skin material composite, such that the recesses extend from the urethane resin skin layer into the cushion layer beyond an interface between the urethane resin skin material and the cushion layer that is present in a region without a recess, as well as a method of producing a synthetic resin skin material composite.

An upholstery member includes a base board (101) having at least one base board opening (116), a fixation arrangement (140), and a resilient wadding (102). The wadding (102) is pressed at least to some extent through the base board opening (116) and connected to the fixation arrangement (140), thereby forming an indent (130) in the upholstery member (100). Further, the invention relates to a method for manufacturing the upholstery member comprising the steps of providing (310) a base board (101) having at least one base board opening (116) and being covered with a wadding (102) on a front side of said base board (101), passing (320) the wadding (102) through said base board opening (116), whereby the indent (13) is formed, and securing (330) the position of the wadding (102) relative the base board (101).

In existing manufacturing methods wherein a bonded seat is formed by adhering a surface skin material to a pad made from molded foam, defects may occur from curing of the adhesive, such as reduced flexibility and a poor texture on the seat contact surface. In addition, the manufacturing steps therefor are complicated. In order to solve the above problems, the present invention provides a manufacturing method for a vehicle seat having a molded pad and a trim cover that covers the molded pad. The molded pad has a groove, and an adhesive is applied to the inside of the groove. The trim cover is pressed into the inside of the groove, and a steam nozzle is inserted into the molded pad from the surface of the molded pad opposite from the surface covered by the trim cover. Heat or steam from the steam nozzle melts the adhesive inside the groove so as to adhere the trim cover to the groove. It is thus possible to provide a vehicle seat and a manufacturing method therefor with which a contact surface can exhibit a good texture and manufacturing steps can be simplified.

A method of manufacturing a mattress that comprises forming a mattress inner core; forming a non-quilted mattress cover; and attaching the non-quilted mattress cover to the inner core without sewing. The non-quilted mattress cover may be formed of a laminate including a polymeric non-woven fabric that may be embossed and cut to include a cover top panel and a plurality of cover side panels that are unitary with and extend outward from the cover top panel. The step of attaching the non-quilted mattress cover to the inner core without sewing includes orthogonally orienting the cover side panels relative to the cover top panel and fusing portions of adjoining surfaces of adjacent cover side panels to each other to form a coffin, inserting the mattress inner core into the coffin, folding non-fused portions of the adjoining surface of the adjacent cover side panels over the mattress inner core, and bonding a bottom panel to the non-fused portions of the cover side panels and the mattress inner core.

A method of manufacturing a mattress that comprises forming a mattress inner core; forming a non-quilted mattress cover; and attaching the non-quilted mattress cover to the inner core without sewing. The non-quilted mattress cover may be formed of a laminate including a polymeric non-woven fabric that may be embossed and cut to include a cover top panel and a plurality of cover side panels that are unitary with and extend outward from the cover top panel. The step of attaching the non-quilted mattress cover to the inner core without sewing includes orthogonally orienting the cover side panels relative to the cover top panel and fusing portions of adjoining surfaces of adjacent cover side panels to each other to form a coffin, inserting the mattress inner core into the coffin, folding non-fused portions of the adjoining surface of the adjacent cover side panels over the mattress inner core, and bonding a bottom panel to the non-fused portions of the cover side panels and the mattress inner core.

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.

An upholstered chair, recliner, or sofa with a frame including a pair blowmolded hollow arm rest forms, wherein frame members extend between the forms. Further components may be blowmolded such as a backrest. The arm rest forms and backrest may be reinforced with metal plates and assembled into a recliner. The connections to the arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust. Upholstery sacks are easily attached to the frame.

An upholstered chair, recliner, or sofa with a frame including a pair blowmolded hollow arm rest forms, wherein frame members extend between the forms. Further components may be blowmolded such as a backrest. The arm rest forms and backrest may be reinforced with metal plates and assembled into a recliner. The connections to the arm rest forms providing a geometrically rigid and robust frame that is weighs less, is quicker to assemble, and is more robust. Upholstery sacks are easily attached to the frame.

Tension-stabilized furniture structures and frame assemblies to form simplified flat packing furniture that eliminates all fasteners, welds and braces. Simplified assembly of pre-tensioned structures providing improved stability, uniformity of support and visual aesthetics. The seat cover material can be netting, fibrous material or textiles. The seating system includes outwardly angled side rails having the profile of furniture, such as seats, couches, chaise lounges, ottomans and the like. The angling of the side rails secures their connection to supporting cross rails with the application of a fitted cover sleeve. The sleeves slidingly engage the frame assembly and provide tension to the frame assembly resulting in highly stable furniture.