An upholstered component, such as panels, assembled onto a furniture frame or a chair mechanism by way of a connection system provides a robust connection and economical manufacturing process. The connection includes a T-nut and a spacer attached on opposite sides of a wood form to be upholstered. The threaded barrel of the T-nut inserted in a hole through the wood form and with T-nut prongs embedding into a surface of the side of the wood form that will be facing outwardly on the furniture. The spacer is inserted into the hole at the opposite side of the wood form and is retained therein by an interference fit. The wood form is upholstered and is then attached to the furniture frame or mechanism with a bolt connecting to the furniture frame or mechanism and then extending through the spacer, into the hole and into the threaded barrel of the T-nut.

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.

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.

A textile deck assembly, method of fabricating, and method of installing onto a seat frame assembly. The textile deck assembly includes a platform portion and a plurality of straps coupled to a rearward edge of the platform portion. The materials of the textile deck assembly are matched so that the plurality of straps undergoes most or all of the elongation under load (e.g., when a person sits thereon), while the platform portion, even though it is flexible and compliant, is stretch resistant and undergoes little or no stretching under load. A battery of durability tests were performed on the textile deck assembly, including deflection testing, fatigue testing, and drop testing, and compared with conventional seat decks that utilize sinuous springs. The durability of the textile deck assembly to was found to outperform conventional seat decks.

A seating structure includes a frame, a carrier, and a suspension material. The frame includes first and second side frame members and first and second cross frame members forming a closed loop and defining an opening therebetween. The frame also includes a plurality of first attachment features on an outer perimeter of the frame. The carrier includes first and second side carrier members and first and second cross carrier members that form a closed loop. The carrier also includes a plurality of second attachment features on an inner perimeter of the carrier. The plurality of second attachment features engages the plurality of first attachment features to attach the carrier to the frame. The suspension material is attached to the carrier and extends over the opening in the frame to define a continuous seat and backrest.

A mesh frame includes a side frame, wherein the side frame includes a first face in contact with a human body during use, the first face being provided with a recess, the recess obliquely extending towards an inner side of the side frame and configured to snap a mesh to the mesh frame.

A seating arrangement includes a rigid back frame, a flexible back shell coupled to the back frame and including a pair of vertical side portions and at least two strap portions extending laterally between the side portions and including a forwardly-facing surface configured to support a back of a seated user, the at least two strap portions including a lowermost strap portion, the lowermost strap portion configured to deflect a first distance when a rearwardly-directed force is exerted on the lowermost strap portion by a seated user, and a lumbar assembly supported from the back frame and configured to support the lumbar region of a back of a seated user, the lumbar assembly configured to deflect a second distance when the rearwardly-directed force is exerted on the lumbar assembly by a seated user, wherein the first distance and the second distance are substantially similar.

A system can include a zipper that connects a mattress to a bed foundation. For example, the zipper can extend from a head end to a foot end of an adjustable foundation. For another example, a zipper can connect to a mattress along a seam of the mattress and/or to a foundation along a seam of a foundation. For another example, a first zipper can connect the mattress core to a second zipper and the second zipper can connect a foundation to the first zipper. For another example, first and second zippers can be substantially vertically aligned.

A seating structure includes a frame, a carrier, and a suspension material. The frame includes first and second side frame members and first and second cross frame members forming a closed loop and defining an opening therebetween. The frame also includes a plurality of first attachment features on an outer perimeter of the frame. The carrier includes first and second side carrier members and first and second cross carrier members that form a closed loop. The carrier also includes a plurality of second attachment features on an inner perimeter of the carrier. The plurality of second attachment features engages the plurality of first attachment features to attach the carrier to the frame. The suspension material is attached to the carrier and extends over the opening in the frame to define a continuous seat and backrest.

A textile deck assembly, method of fabricating, and method of installing onto a seat frame assembly. The textile deck assembly includes a platform portion and a plurality of straps coupled to a rearward edge of the platform portion. The materials of the textile deck assembly are matched so that the plurality of straps undergoes most or all of the elongation under load (e.g., when a person sits thereon), while the platform portion, even though it is flexible and compliant, is stretch resistant and undergoes little or no stretching under load. A battery of durability tests were performed on the textile deck assembly, including deflection testing, fatigue testing, and drop testing, and compared with conventional seat decks that utilize sinuous springs. The durability of the textile deck assembly to was found to outperform conventional seat decks.