A seat unit is provided comprising a base structure and at least one cushion layer comprised of a random mesh of plastic filament between the base structure and the cover layer. The cushion layer not only provides adequate firmness, but has adequate air circulation therethrough. The perimeter of the cushion may be molded in with a plastic base structure, and there may be multiple cushion layers where each layer has a different density. The multiple layers of cushioning where each layer has a different density further allow the seat to have both a specifically desired firmness and air circulation therethrough. Also provided is a method for molding in the cushioning with the base structure as well as molding in a spring layer and a cover layer.

The present invention realizes spreading a sheet on a frame member by a simple structure and a simple process, and prevents uneven tension charged against the sheet. In the sheet spreading method of the invention, a core member for a backrest of a chair which is heated to around 200.degree. C. in a furnace is put into a flow dipping tank filled with powder resin. As a result, a resin coating is formed on the surface of the pipe constituting the core member. Also, a mesh is placed on a metal mold and clamped. Since a recess corresponding to the shape of the core member is formed in the top side of the metal mold, the mesh is spread on the core member with a tension charged against when the core member having the above-mentioned coating is pressed into the recess.

A method and system for capturing support materials in carrier frames in the manufacture of seat components for chairs including moving the support material to an openable mold press forming a mold cavity for the carrier frame when the mold press is closed, shaping the support material, and molding the carrier frame to capture the shaped material in the carrier frame. In one embodiment, the support material is stretched as it is moved to the mold press, and/or in the mold press before molding the carrier frame. Excess support material is removable from an outer side portion of the carrier frame after molding the carrier frame and before discharging the carrier frame and support material captured thereby from the mold press.

An improved support area for use with rattan furniture. The present invention provides a frame, a seat contact portion, and a back contact portion. In various embodiments, the chair includes a seat cushion that is supported by a seat support portion of the frame. The seat cushion is covered on its outside by a rattan outer layer that is attached to the seat support structure such that the rattan outer layer conforms to the shape of the seat cushion and the presence of the seat cushion is obscured by the rattan outer layer. In other embodiments, the back support portion may include a similarly configured back cushion. As a result, the present invention has the appearance and aesthetic appeal of a typical article of rattan furniture, having rattan seat and back surfaces, however the present invention provides a level of comfort that is not typically provided by rattan seat and/or back surfaces.

A simple and inexpensive method and apparatus for molding a peripheral frame around a sheet or grid of thermoplastic material to produce a framed panel. A peripheral frame, preferably of structural foam or the like, is injection molded about a thermoplastic sheet or grid of panel-forming material which has been previously drawn or stretched at a temperature which orients the molecules of the polymer, i.e., below the glass transition temperature of the polymer, T.sub.g. Either during the frame molding process, or subsequent thereto, the panel-forming material is heated sufficiently to cause the material to shrink or revert toward its prestretched condition so as to tension the panel-forming material within the frame. Elastomeric sealing means are disclosed for sealing the mold during injection of the frame-forming material and locator fingers are provided to position a grid-like panel-forming material prior to initiation of the molding process. By the utilization of structural foam molding techniques, a panel of thermoplastic material may be integrally-molded and tensioned within a rigid frame to produce a framed panel of any size for use as a barrier, a fence, a guard, a closure, a seat or bedding support, a filter member or other such applications.