Dual Density Foam

No Butts about it – Karo Manufacturing’s latest seating technology sets a new standard in ergonomic comfort, support and cushioning.
The new DUAL DENSITY seat incorporates two levels of firmness – both constructed from durable, CFC-free moulded polyurethane foam which provide differing deflection characteristics, encouraging an anatomically-correct posture, to reduce backache and muscle fatigue normally associated with the ‘slump posture’ often seen in foam-based seats.

The conical discs are interconnected by a foam link, which forms a cut-away shape for the coccyx, allowing the tail bone to comfortably ‘float’.
The gradual transitional slope opens the pelvis and also creates a negative tilt, which improves blood flow to the legs.
Clinically proven enhancements in blood and oxygen flow as a result of postural change can help aid concentration levels and improve overall office efficiency.

Dual-Density-on-Equinox-Cut--away

Dual-Density-on-Equinox-Cut–away

Dual-Density-Detail

Dual Density Foam detail on cut-away Seat

Widely used in the automotive industry, this cutting-edge technology has long been recognised by ergonomists, occupational health and medical professionals as being able to deliver the best support and cushioning, offering super-comfort over a variety of different body weights.

Conventional single density foam does not offer suport where it is specifically needed

Conventional single density foam does not offer support where it is specifically needed

Our Dual Density Foam offers support in those areas where it is needed

Our Dual Density Foam offers support in those areas where it is needed

The smart technology of Karo’s DUAL DENSITY seat delivers extraordinary comfort and offers the user a customised seating experience.

Some seating with inferior pressure distribution patterns could ultimately increase disc pressure in the lumbar and coccyx areas, causing unhealthy long term effects.

When a person is in a seated position, his or her weight typically rests on a section of bone called the Ischial Tuberosity. When standing, the Gluteus Maximus muscle lies over it however, when one sits down, the muscle shifts to a position behind it and the tuberosity bears the majority of the weight.

The firmness gradient in the 3-D conical shape of the DUAL DENSITY seat pinpoints load absorption and Indentation Load Deflections (*ILD) and allows the higher density foam to “push back” against the weight thus preventing the foam from “bottoming out”. This helps avoid the feeling of having the foam collapse beneath body weight. It restores normal positioning and curvature of the spine and reduces sciatic nerve pain.

*ILD – Indentation Load Deflection – the measure of how much pressure it takes to compress foam to 25% of its thickness.

Comfort-level-Conventional-foam

For conventional foam, the perceived comfort level deteriorates during the course of the day

Comfort-level-Dual-density

For Dual Density foam, the perceived comfort level is maintained during the course of the day

At Karo, striving for manufacturing excellence is relentlessly pursued by all employees, so much so that we believe continual improvement is in our DNA.

In our quest for perfection, we have recently commissioned a state-of-the-art computer controlled GERBER fabric cutter to accurately cut all our upholstery fabrics and vinyls. This automated high-speed precision cutting system from the USA, uses a superbly engineered cutting wheel in conjunction with a powerful vacuum system to hold material firmly in place during cutting, thereby guaranteeing the quality of all cut parts. Using the GERBER cutter to accurately cut all upholstery pieces, greatly enhances the precision of the ensuing sewing and upholstery process, which in turn directly improves the quality of our office chairs. Of particular importance for those customers that upholster their office chairs with a striped or patterned fabric, we are able to use the system’s database to accurately record how a specific upholstery fabric was cut, thereby ensuring that even years later, subsequent chair orders are upholstered to exactly match the earlier orders. By eliminating manual fabric cutting at Karo, we have improved the quality of our office chairs and so taken another step on our continual improvement journey.

Karo….improving quality with affordable innovation.

 

Gerber Cutter

Gerber Cutter

Gerber Cutting Head Detail

Gerber Cutting Head Detail

Perfectly Cut Panels

Perfectly Cut Panels


Why Insist on Moulded Foam ?

It’s well documented, that the right office chair with proper support can increase productivity and maximise efficiency in the workplace.
One key factor in achieving optimum ergonomic support, is to ensure the seat is manufactured from moulded foam, rather than block-cut or ‘slab’ foam.
Widely used in the automotive industry, moulded foam has long been recognised by ergonomists, occupational health and medical professionals as being able to deliver the best support and cushioning, offering superlative comfort over a variety of body weights.
Moulded foam:-
• Is resilient and maintains its shape without collapsing over time, offering longer chair life
• Seats can be tailor-made, ranging from very soft to extremely firm seating, depending on the design and function of the chair
• Can be moulded into a variety of shapes with contours, for optimum ergonomic comfort
• Is more durable than block-cut foam and easily meets 5+ year guarantee requirements
• Has no off-cuts or wastage during production and thus, is kinder to the environment
Karo boasts their very own in-house state of the art foam plants, where the shape and density of each and every seat is monitored, to ensure optimum quality and comfort.

Pouring into a Mould

Moulded Foam stacked for Curing

Moulded Foam Back Rest for Monte Carlo Chair

Cross Section through a Moulded Foam Seat

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