Method and device for producing a vehicle interior part

Abstract

An apparatus and method for producing a vehicle interior trim component may include creating a plurality of molten polymer filaments, and applying a flow of fluid to the molten filaments in a bath to cool the molten filaments to impart a desired shape and then form a consolidated filament structure. An assembly, system, and method are provided for forming a plurality of molten thermoplastic resin strands into a shaped integral web product via at least one forming conveyor belt. Another assembly, system, and method are provided for shaping a plurality of molten thermoplastic resin strands into a shaped integral web product via an actuator assembly having one or more actuators.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of Danish (DK) patent application No. PA202370255 filed on May 26, 2023, U.S. Provisional Application Serial No. 63 / 355,809 filed on June 27, 2022, U.S. Provisional Application Serial No. 63 / 356,549 filed on June 29, 2022, and U.S. Provisional Application Serial No. 63 / 503,292 filed on May 19, 2023, the disclosures of which are hereby incorporated by reference in their entirety. Technical Field

[0002] Various embodiments of the present disclosure are directed to a method and apparatus for producing vehicle interior components, seat pads, and components, systems, and methods for manufacturing or forming seat pads. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 shows a schematic diagram of a system and method according to embodiments described herein; Figure 2 shows a schematic diagram of a system and method according to embodiments described herein; Figure 3 shows a consolidated filament structure for use as a cushion blank for forming a vehicle seat having side bolsters according to embodiments described herein; Figure 4 shows a consolidated filament structure for use as a cushion blank for forming a vehicle seat having a concave center portion according to embodiments described herein; Figure 5 shows a consolidated filament structure for use as a cushion blank for forming a vehicle seat having a channel according to embodiments described herein; Figure 6 is a front perspective view of a seat assembly according to some embodiments; Figure 7 According to some embodiments Figure 6 A front partial perspective view of a cushion of a seat assembly; Figure 8 It is used to manufacture Figure 7 A front elevation schematic diagram of a system for a seat pad; Fig. 9 According to some embodiments Figure 8 A front elevation schematic diagram of a transmission component of a system; Fig.10 According to some embodiments Figure 8 A front perspective schematic diagram of a transmission component of a system; Fig.11 It is used Fig. 9A front elevation view of a liner manufactured by a conveyor assembly; Fig.12 According to some embodiments Figure 8 A front elevation schematic diagram of a transmission component of a system; Fig.13 It is used Fig.12 A front elevation view of a liner manufactured by a conveyor assembly; Fig.14 According to some embodiments Figure 8 A schematic side elevation view of an actuator assembly for use with a system; Fig.15 yes Fig.14 A schematic top perspective view of an actuator assembly; Fig.16 shows a schematic diagram of a system having a component and one or more subcomponents according to some embodiments; Fig.17 A method for forming and shaping a product having an assembly and one or more subassemblies is shown according to some embodiments; and Fig.18 Methods for forming and shaping a product are shown according to some embodiments. Detailed Description

[0004] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the detailed description that follows, many specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it is apparent to one of ordinary skill in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely exemplary, and that different and alternative forms are possible. The drawings are not necessarily to scale; some features may be exaggerated or reduced in order to show the details of particular components. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to implement the embodiments according to the present disclosure in various ways.

[0006] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0007] It should also be understood that, although in some cases, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact without departing from the scope of the various embodiments described. Both the first contact and the second contact are contacts, but they are not the same contact.

[0008] The terms used in the description of the various embodiments described herein are used only for the purpose of describing specific embodiments and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any and all possible combinations of one or more of the relevant listed items. It should be further understood that when used in this specification, the terms "includes", "including", "comprises", and / or "comprising" specify the presence of the features, wholes, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts, and / or groups thereof.

[0009] As used herein, the term "if" is optionally interpreted to mean "when..." or "upon..." or "in response to determining..." or "in response to detecting...", as the context requires. Similarly, the phrases "if it is determined" or "if [the condition or event] is detected" are optionally interpreted to mean "upon determining..." or "in response to determining..." or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]", as the context requires.

[0010] The term controller can be provided as one or more controllers or control modules for various components and systems. Controllers and control systems can include any number of controllers and can be integrated into a single controller, or have various modules. Some or all controllers can be connected via a controller area network (CAN) or other systems. It should be appreciated that any controller, circuit or other electrical device disclosed herein can include any number of microprocessors, integrated circuits, memory devices (e.g., flash memory (FLASH), random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variants of these memory devices) and software, which work together to perform the operations disclosed herein. In addition, any one or more of the electrical devices disclosed herein can be configured to execute a computer program contained in a non-temporary computer-readable medium, which is programmed to perform any number of functions disclosed herein.

[0011] refer to Figure 1 , shows a schematic diagram of a system 10 that can be used with the method 11 according to the embodiments described herein. A hopper 12 contains solid particles of a polymer material 14 to be extruded. In some embodiments, the material 14 is a linear low density polyethylene (LLDPE), although the methods described herein can be used to produce finished products using different types of polymers as needed and effective. The material 14 is fed from the hopper 12 to an extruder 16. The extruder 16 melts the material 14 and conveys the material 14 to a die arrangement 18 including a die plate 20. The extruder 16 can be, for example, a conventional extruder including a barrel that receives a rotatable screw. The rotation of the screw forces the material 14 to move through the barrel and helps to heat the material due to the friction generated when the screw rotates. A heating element can be disposed on the barrel and heats the polymer material 14 in the barrel.

[0012] The material 14 exits the extruder 16 at location 22 under pressure and in a molten state. Unless otherwise specified, the term "molten" as used herein means that the material is at least partially molten. This does not mean that the material must be in a completely liquid state; rather, it means that the material is not completely solid and is still able to flow through the elements of the system 10. For example, the molten material is still able to flow through the die plate 20, but it may be very viscous and begin to solidify. Once the solid particles of polymer material 14 are melted in the extruder 16, the material will begin to cool as it stops being agitated by the extruder screw and moves away from any heaters. At different points in the process 11, the material may have a higher or lower viscosity, but if it is still partially molten and able to flow - even slowly - the term "molten" applies herein.

[0013] The die plate 20 extrude the material 14 into filaments 24. More specifically, the die plate 20 has a plurality of holes 21 disposed therethrough (for clarity, the holes are not shown in FIG. Figure 1 Only some of them are marked in the figure), the molten material 14 passes through these holes. A single filament 24 is extruded from each template hole. The filaments 24 fall downward from the template 20 to the funnel 26 under the system pressure and gravity. The funnel 26 helps the filaments 24 to consolidate or group into a more compact arrangement, the filaments are bent or looped in the funnel 26, and each filament 24 contacts and bonds to at least one other filament 24. In some embodiments, the funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. More specifically, the funnel 26 is narrower at the funnel outlet 30 than at the funnel inlet 28. Individual separated filaments 24 enter the funnel inlet 28, and then the filaments 24 are bent or looped and move into contact with each other as they accumulate and slide down along the funnel 26 toward the funnel outlet 30, and the consolidated filament structure 32 leaves the funnel outlet 30 and enters the water tank 34. When the filaments 24 reach the funnel 26 , those filaments near the outer portion of the funnel 26 —approximately 2 to 3 rows —slide down the angled surface of the funnel 26 , which creates a skin on the consolidated filament structure 32 .

[0014] Water tank 34 holds water 36 and receives the consolidated filament structure 32 from funnel 26. Water 36 performs at least two functions. First, it helps to temporarily support the consolidated filament structure 32 to prevent it from collapsing or shrinking into a less open or less porous arrangement. Therefore, water 36 provides some resistance, which causes the extra bending and looping of long filaments 24 to further build the consolidated filament structure 32. Secondly, water 36 cools the polymer filaments 24 from the outside to solidify it. The temperature of water 36 can be much lower than the temperature of the filaments 24 when the filaments 24 leave template 20, for example, water can be in the temperature of the surrounding environment around box 34. Although the fluid used in this embodiment is liquid water 36, in other embodiments, other types of fluids can be used.

[0015] The water tank 34 includes various rollers and conveyors that help move the consolidated filamentary structure 32 through and out of the water 36. A traction conveyor 38 is submerged in the water 36 and engages opposite sides of the consolidated filamentary structure 32 to move the consolidated filamentary structure 32 away from the hopper 26 at approximately the same speed as the consolidated filamentary structure 32 exits the hopper 26. The gap between opposing portions of the traction conveyor 38 is slightly narrower than the width of the consolidated filamentary structure 32 to allow the traction conveyor 38 to better grip the consolidated filamentary structure 32. As previously described, Figure 1 is a schematic diagram and has been simplified for the purpose of illustration. For example, a conveyor belt such as the traction conveyor belt 38 may be as shown in FIG. Figure 1The neutral orientation is located toward the front and rear of the system 10, rather than on the left and right sides as shown.

[0016] Another roller 40 helps keep the consolidated filamentary structure 32 submerged and helps guide it through the water 36 toward a conveyor belt 42 and a vibrating table 44 located outside the water tank 34. While the consolidated filamentary structure 32 is on the conveyor belt 42, the vibrating table 44 vibrates the consolidated filamentary structure 32 to remove at least some of the water 36. Pressurized air may also be blown toward the consolidated filamentary structure 32, which may also be squeezed to remove more water 36. Finally, the consolidated filamentary structure 32 may be cut into a desired size and shape.

[0017] Figure 2 Shows similarity to Figure 1 4. The portion of system 46 of system 10 shown in FIG. 4 can be used to perform method 48 according to embodiments described herein. System 46 includes a die plate 50 having a plurality of holes disposed therethrough, which can be positioned in an extruder such as an extruder. Figure 1 At the end of the extruder 16 shown. Similar to the combination Figure 1 The method 11 described herein forms a plurality of molten polymer filaments 52 (for clarity, only the filaments 52 are shown in Figure 11 ) as the molten polymer moves through the holes in the template 50. Figure 2 5 (some of which are labeled in FIG). Molten polymer filaments 52 move downward from die plate 50 into funnel 54, which helps consolidate the molten polymer filaments and directs the molten polymer filaments into a fluid bath 56, which, as described above, can be used to cool the molten polymer. In this embodiment, bath 56 is a tank filled with water 58, but in other embodiments, a fluid bath such as fluid bath 56 can be filled with a fluid other than water, depending on the particular application.

[0018] As the molten polymer filaments 52 enter the fluid 58, the molten polymer filaments 52 begin to cool and form a solidified filament structure 59. At this stage, the filaments 52 are just beginning to form a more solidified structure, but are still in a compliant state. More specifically, the filaments 52 that form the beginning portion of the solidified filament structure 59 can be moved and arranged into different shapes that will remain when the filaments 52 are fully solidified. The traction conveyor 60 engages the solidified filament structure 59 to move it away from the funnel 54. Similar to Figure 1 As shown in the system 10, the system 46 may include additional rollers, conveyors, etc. to guide the filament structure 59 through the rest of the system 46. Figure 2As shown, the system 46 also includes a conduit arrangement 62 having several conduits 64. The conduits 64 may be configured, for example, as tubes for applying a fluid flow to the molten polymer filaments 52 as they begin to cool in the fluid bath 56. On the opposite side of the consolidated filament structure 59 is another conduit or tube 66 that is also configured to apply a fluid flow to the filaments 52 as they begin to cool in the water bath 56.

[0019] According to the methods described herein, the tubes 64, 66 can be used to apply a fluid flow to the molten polymer filaments 52 so that the filaments 52 are imparted with a desired shape, thereby forming a consolidated filament structure having a desired shape. Figure 2 In the illustrated embodiment, there are three tubes 64 of the plurality of tubes on one side of the filament 52 and one tube 66 of the plurality of tubes on the other side of the filament 52. In other embodiments, different catheter arrangements with different numbers of tubes may be used. For example, a catheter arrangement as used with the embodiments described herein may have a plurality of tubes, such as: Figure 2 In the "stacked" arrangement of the tubes 64 shown in FIG. 5 , they can be placed horizontally in a row, or they can be positioned in an array pattern to achieve a desired shape. As described above, the tubes 64, 66 are configured to apply a fluid flow to the filaments 52.

[0020] exist Figure 2 In the embodiment shown, the fluid used for the fluid flow is water taken from a water tank 58. A pump or other device can be used to force the fluid through the tubes 64, 66 and toward the filaments 52. In other embodiments, other fluids can be used, including liquids other than the liquid that fills the tank 56, or the fluid can be mostly or completely gaseous, so that air or some other gas flows toward the filaments 52. Similarly, Figure 2 As shown, tube 64 and tube 66 are positioned to apply fluid flow in two different directions, i.e., tube 64 applies a fluid flow directly opposite to the fluid flow applied by tube 66. In other embodiments, one or more tubes may apply fluid flow in a single direction or in different directions that are not opposite to each other.

[0021] Each tube 64 includes a nozzle 68 located at its end closest to the filament 52. Similarly, tube 66 has a nozzle 70 located at its end closest to the filament 52. These nozzles 68, 70 can be converging, that is, having an outlet opening that is smaller than the inner diameter of the tubes 64, 66. Alternatively, the nozzles 68, 70 can be diverging, that is, the nozzles 68, 70 can act as diffusers having an outlet opening that is larger than the inner diameter of the tubes 64, 66. In some embodiments, different combinations of converging nozzles and diverging nozzles can be used to achieve the desired shape of the consolidated filament structure 59. Figure 2In the illustrated embodiment, the nozzles 68, 70 are positioned approximately 10 millimeters (mm) to 15 millimeters (mm) from the surface of the filament 52, although in other embodiments, the nozzles 68, 70 may be positioned closer or further away from the filament, depending on the desired effect. Although the tubes 64, 66 are shown on opposite sides of the filament 52, in other embodiments, one or more tubes may be placed at different locations around the exterior of the filament 52, again based on the desired final shape of the consolidated filament structure 59.

[0022] As the molten polymer filaments 52 begin to cool and form the consolidated filament structure 59, the molten polymer filaments 52 will become increasingly solidified - this is shown at the lower portion 72 of the consolidated filament structure 59, which is located near the end of the traction conveyor 60. Figure 2 As shown, fluid flowing through nozzle 68 contacts polymer filaments 52 and forms recesses or channels 74 in the consolidated filament structure 59. Similarly, fluid flowing through nozzle 70 on the side opposite to conduit arrangement 62 forms recesses or channels 76-78 in the other side of the consolidated filament structure 59. Various shapes can be imparted to consolidated filament structures, such as consolidated filament structure 59, depending on the size, shape, and array of the tubes and associated nozzles.

[0023] This flexibility may be particularly convenient when the consolidated filament structure is intended for use as a vehicle interior component. For example, the consolidated filament structure 59 may be used as a cushion blank for a portion of a vehicle seat. In order to reduce time and cost, particularly in post-processing operations, the consolidated filament structure 59 may be formed using the systems and methods described herein to produce a mesh or near-mesh structure. For example, the channels formed by the fluid stream may be positioned on either side of the seat liner to help form side pillows or other desired features. Figure 3 A consolidated filament structure forming a liner blank 80 produced using embodiments such as described above is shown.

[0024] Specifically, the embodiments described herein are used to apply a fluid flow to a Figure 2 The molten polymer filaments of the fluid box shown in the figure are used to form two channels 82, 84 on either side of the liner blank 80. Two side pillows 86, 88 are located on opposite sides of the liner blank 80, adjacent to the corresponding channels 82, 84. Figure 3As shown, the side pillows 86, 88 can be formed by applying a fluid stream on the side of the liner blank 80 opposite the channels 82, 84 to push the side pillow portions 86, 88 upward. Alternatively, the center portion 90 of the liner blank 80 can be subjected to an array of fluid streams to push it downward so that the side pillow portions 86, 88 rise above the surface 92 of the center portion 90. Some combination of these two techniques can also be used. In this way, using a combination of fluid streams such as Figure 2 The fluid flows described are used to produce a consolidated filament structure having a desired shape.

[0025] Embodiments of the systems and methods described herein can also be used to form different types of shapes that can be used in different applications. For example, Figure 4 A consolidated filament structure 94 is shown that is also intended for use as a cushion blank for a vehicle interior component such as a vehicle seat. The filament structure 94 includes a slightly concave center portion 96 formed by an array of fluid streams that contact the side of the molten polymer filaments as they move through the fluid bath. In this embodiment, the side portions of the cushion blank 94 are not so distinct as to be side bolsters, but the center portion 96 is slightly lower than the side portions, which creates a desired shape for a seated occupant. Figure 5 , another consolidated filamentary structure 98 is shown. The filamentary structure 98 is also configured for use as a cushion blank, and in this embodiment, a channel 100 is formed in the surface of the cushion blank 98. The channel 100 can form a convenient location for a sewn seam on a trim cover, which is typically drawn into a channel or other recess in the cushion material to provide a more aesthetically pleasing finished product.

[0026] Figure 6 The seat assembly 120 is shown as a vehicle seat assembly 120 according to some embodiments. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be used. The seat assembly 120 may be used in a land vehicle, an aircraft, a boat, etc. The seat assembly 120 may also be used in an office chair, a comfort chair, etc.

[0027] The depicted seat assembly 120 includes a seat bottom pad 122 to support the pelvis and thighs of the seated occupant. The seat assembly 120 also includes a seat back pad 124 to support the back and shoulders of the seated occupant. A trim cover 126 is disposed over the seat pads 122, 124 to conceal the seat pads 122, 124 and provide a uniform and smooth contact surface for the occupant.

[0028] Reference now Figure 7, one of the seat pads 122 is partially shown separated from the seat assembly 120. The seat pad 122 is formed from a plurality of strands 128 of an extruded, expanded thermoplastic resin. The seat pad 122 is also formed with a base layer 130 that is bonded to and / or integrally formed with the plurality of strands 128.

[0029] Reference now Figure 8 , the seat pads 122, 124 are manufactured by a system 132 and process for extruding a thermoplastic resin web. In the depicted embodiment, the extruder 134 provides pressurized molten thermoplastic resin to an extrusion die 136. The extrusion die 136 is arranged with a plurality of outlet ports or nozzles 138 to distribute a plurality of molten thermoplastic resin strands 128. The strands 128 are distributed through a funnel plate 140 and distributed into a fluid chamber 142. The funnel plate 140 guides the strands 128 into the fluid chamber 142. The fluid chamber 142 holds a fluid, such as water, to resist and cool the strands 128. The fluid chamber 142 resists the flow of the strands 128, thereby causing the strands 128 to buckle, loop and cross-link with adjacent strands 128 within a profile defined by the funnel plate 140. The strands 128 may also expand and float within the fluid chamber 142. The strands 128 are fluid cooled in the fluid chamber 142 to form an integral nonwoven thermoplastic liner 122. According to the method, the nonwoven thermoplastic liner 122 is fluid cooled, cooled, and solidified.

[0030] The system 132 includes a conveyor belt assembly 144 in the fluid chamber 142. The conveyor belt assembly 144 conveys the plurality of strands 128 through the fluid chamber 142. The conveyor belt assembly also provides an outer boundary for the strands 128 so that the strands 128 are shaped to have a shape as the cushion 122. Otherwise, a conventional conveyor belt would produce a cushion with a rectangular cross-section. However, the shaping of the seat cushion 122 is used to support and comfort the occupant. The conveyor belt assembly 144 is a shaping conveyor belt used to form the shape in the cushion 122.

[0031] The conveyor belt assembly 144 is Fig. 91. The conveyor belt assembly 144 includes a pair of conveyor belts 146, 148. The conveyor belts 146, 148 are used to form shapes or features on the mesh liner 122. The conveyor belts 146, 148 press the shapes into the mesh liner 122 within the fluid chamber 142 before the mesh liner 122 solidifies and solidifies into its final shape. As the strands 128 enter the fluid, a preliminary shape is formed into the mesh liner 122 at the initial area. For example, based on one example of the funnel plate 140 and the template 136, the conveyor belts 146, 148 can engage the strands 128 within the first inch of the fluid. The conveyor belts 146, 148 remain in contact with the liner 122 until the mesh 122 solidifies, for example, about 6 inches into the fluid.

[0032] Each of the conveyor belts 146, 148 includes a track 150, 152 for traveling around the conveyor belts 146, 148 to convey the web 122 between the tracks 150, 152. Fig. 9 In the embodiment of FIG. 1 , track 150 runs clockwise; and track 152 runs counterclockwise. Fig.10 As shown, each of the tracks 150, 152 includes a plurality of links 154 pivotally interconnected as chain link tracks 150, 152. According to one example, each track 150, 152 includes 96 links 154 having flat or contact surfaces. Alternatively, the tracks 150, 152 may be formed by belts or the like.

[0033] Reference again Fig. 9 , a plurality of forming tools 156 are attached to the track 150 to form shapes, features, and / or moldings 158 in the mesh cushion 122. The forming tools 156 are modular and attached to the track 150. For automation flexibility, the forming tools 156 are replaceable so that the forming tools 156 can be replaced to make a variety of different cushion 122 designs between the tracks 150, 152. Alternatively, the tracks 150, 152 can be configured to form multiple cushion 122 designs to make a variety of seat cushions 122 on one system 132.

[0034] Fig. 9 The conveyor belts 146, 148 are shown positioned parallel, spaced apart, and facing each other. Fig.10 A third conveyor belt 160 is shown as also being used to constrain a third side of the liner 122 during the forming and cooling process. The third conveyor belt 160 is positioned adjacent to and perpendicular to the conveyor belts 146, 148. A fourth conveyor belt (not shown) may also be utilized and positioned spaced apart and parallel to the third conveyor belt 160 to constrain and form all sides of the liner 122. Of course, any number of conveyor belts 146, 148, 160 may be utilized.

[0035] like Fig.11 As shown, the mesh cushion 122 is shown in a final cured shape 122 with a plurality of recessed features 158 formed by a forming tool 156. The recessed features 158 may create shapes, moldings, test marks, position marks, contact surface features, grooves, or features for attaching the cushion 122 to a seat frame, seat trim, actuator, heat transfer device, etc. By forming the recessed features 158 while forming the mesh cushion 122, secondary forming operations may be minimized or omitted. Instead of forming a mesh cushion 122 having a plurality of recessed features 158 formed by a forming tool 156, the recessed features 158 may be formed by a forming tool 156. Figure 7 The rectangular cross-section of the pad 122 is shown, Fig.11 The liner 122 is formed with a shape that requires less secondary forming or cutting operations. The forming tool 156 can be set on any one of the conveyor belts 146, 148, 160.

[0036] Fig.12 A conveyor belt assembly 162 is shown according to another embodiment. The conveyor belt assembly 162 includes a pair of spaced apart and parallel conveyor belts 164, 166. Similar to the previous embodiment, the conveyor belt assembly 162 is positioned with the fluid chamber 142 to receive, shape and convey the molten thermoplastic strands 128. The linear actuator 168 cooperates with the conveyor belts 164, 166 to change the spacing between the conveyor belts 164, 166 for forming the web 122. As the web 122 is formed, cooled and translated through the conveyor belts 164, 166, the conveyor belts 164, 166 are actuated.

[0037] Fig.13 Shown by Fig.12 The liner 170 is formed by the conveyor belt assembly 162. The liner 170 includes a shape 172 formed during the formation and conveying of the web 122 by the conveyor belt assembly 162. Referring again to Fig.12 The linear actuator 168 communicates with the controller 174 for controlling the linear actuator 168 to actuate one or more of the conveyor belts 164, 166. Various mesh pads 170 having various shapes 172 are manufactured by the conveyor belt assembly 162 without changing the tooling of the conveyor belt assembly 162. Various pads 170 are manufactured by operating various programs using the controller 174.

[0038] Figure 8 The fluid chamber 142 in the seat cushion 122 serves as a heat transfer chamber 142. The fluid chamber 142 is used to cool the web 122 to solidify and bond the strands 128. The fluid chamber 142 can also be used to heat the web 122. For example, the inlet area of ​​the fluid can be heated, while subsequent areas of the fluid can be cooled to aid in the shaping and forming of the cushion 122. For example, the fluid can be heated to 130 degrees Fahrenheit in the entry area of ​​the fluid chamber 142. The heating and cooling settings can vary for various seat cushion 122 designs.

[0039] Figure 14 to Figure 151 and 2 show a side view and a top view, respectively, of an actuator assembly 200 according to some embodiments. According to one non-limiting example, the actuator assembly 200 may be used with the system 132 to replace Figure 8 142, or as a supplement to a conveyor belt assembly 144 that assists in moving the strands 128 through the fluid chamber 142. The actuator assembly 200 can be at least partially positioned within or immersed in the fluid chamber 142. The actuator assembly 200 is moved and controlled to provide an outer boundary to the strands 128 so that the strands 128 are shaped to have, for example, the same shape as the cushion 122, and to provide a non-rectangular cross-section for the cushion 122. However, the shaping of the seat cushion 122 is used to support and comfort the occupant. The actuator assembly shapes and forms the shape in the cushion 122 by applying a force on the strands 128 to locally displace or squeeze the strands and form features 158.

[0040] The actuator assembly 200 includes one or more actuators 202, such as an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, etc. In one non-limiting example, the actuator 202 is configured as a linear actuator.

[0041] A controller 204 is provided for controlling the position of each actuator 202. The controller may be similar to the controller described above with respect to controller 174.

[0042] The actuators 202 can be arranged in one or more arrays 206. In the example shown, there are two arrays 206 of actuators 202, where the arrays are located on opposite sides of the strands 128 in the assembly 200 to apply force or pressure to one or both sides of the strands 128.

[0043] In other examples, only a single array may be provided, or more than two arrays may be provided. In one example, a single array 206 is provided on only one side of the strand 128, wherein a non-moving back support for forming the strand 128 is provided opposite the array 206.

[0044] In another example, there may be arrays 206 disposed on all four sides of the assembly 200 to shape all four sides of the strand 128 as it moves through the assembly.

[0045] Each actuator array 206 may include a row 207 including a plurality of actuators. Each array 206 may additionally include one or more layers of rows of actuators.

[0046] In the example shown, there are three layers 208 in each array 206, such as Fig.14 , but arrays 206 having fewer than three layers or more than three layers are also contemplated. Fig.15One layer 208 or top layer in each of the arrays 206 is shown because Fig.15 is a top view of assembly 200. As shown, rows of layers 208 may be positioned to stack in the direction of travel of the product.

[0047] Although the actuator arrays 206 illustrate the actuators 202 arranged in linear rows 207 within each layer and moving in a common direction, it is also contemplated that the actuators 202 may be arranged along curved or other shaped rows or paths and may additionally or alternatively move in different directions relative to each other. For example, an actuator 202 in one array 206 may be positioned to move at an angle (such as an acute angle) relative to another actuator 202 in the same array 206, which may allow for other profiles or shapes of the strands 128 and resulting pads 122.

[0048] The assembly 200 provides computer controlled forming assembly or looping for strands 128 using actuators 202 in arrays 206. By providing multiple layers 208, the overall shaping surface can be increased to contact and shape the strands. The actuators 202 of the assembly 200 can be at least partially immersed in the fluid chamber 142 to produce a desired form and profile for the cushion 122. The assembly 200 can be configured to continuously form or shape the strands 128 using arrays 206 of actuators 202. By controlling the position of the actuators 202 in each array 206 as the strands 128 move through the assembly 200 via the controller 204, the profile or shape of the resulting cushion 122 can be dynamically controlled.

[0049] Each actuator is provided with a head 210 at the distal end of the moving actuator arm or member. The head 210 can be provided in a variety of shapes and sizes, and can have curved, planar, or other shaped surfaces that interact with the stranded members 128. In one example, the head 210 is coated or formed of a rubber material such as natural rubber or synthetic rubber, for example, to provide additional compression to the strand material 128.

[0050] In one example, the head 210 of the actuator 202 directly contacts and engages with the strands 128 within the assembly 200. In another example, one or more flexible and / or elastic layers 212 can be disposed between the head 210 of the actuator and the strands 128 within the assembly such that the head 210 of the actuator 202 contacts the layer 212, which in turn contacts the strands 128.

[0051] The controller 204 can control the actuators 202 independently or individually, and can additionally actuate one or more actuators 202 (e.g., as a group) to provide various styles, shapes, and contours to the cushion 122 by shaping the outer surface of the strand bundle 128 within the assembly 200. In one example, opposing actuators 202 are actuated to compress the strand material 128. The individual heads 210 of the actuators 202 cooperate to compress the outer peripheral surface of the strand material 128 to produce an overall contoured shape. For example, the controller 204 can control the actuators 202 based on the desired cushion 122 shape, and the actuator 202 control can be based on the cushion 122 being segmented or sliced ​​to correspond to the layers 208 in the array 206.

[0052] The controller 204 can additionally control the actuation distance or stroke of each of the actuators 202 to control the final profile and shape of the cushion 122. Furthermore, the controller 204 can control the actuation time, or the time that the actuator 202 is in the deployed position or in contact with the strand material 128, to control the resulting profile and shape of the cushion 122. In one example, the stroke can be controlled by controlling the air pressure to the actuator.

[0053] The controller may receive a signal indicating the speed of the strands 128 through the assembly 200 or the feed rate of the strands to control the actuator 202 to provide the desired profile and shape of the cushion. The controller 204 may also additionally provide a signal to the extruder 134 to control the flow rate or running rate of the strands 128 from the extruder 134.

[0054] After the strand 128 leaves the assembly, for example Fig.14 As shown through the bottom of the assembly 200 , the strands 128 may be cut to form individual pads 122 .

[0055] The actuator 202 is used to form shapes or features on the mesh backing 122 by pressing the shapes into the mesh backing 122 within the fluid chamber 142 before the mesh backing 122 cures and settles into its final shape.

[0056] The actuator 202 can be controlled and selectively actuated to form a mesh liner 122 having a shape, recess or feature 158 as described above or other shapes. By forming the shape and recess features 158 while forming the mesh liner 122, secondary forming operations can be minimized or omitted. Instead of forming a mesh liner 122 having a shape, recess or feature 158 as described above, the mesh liner 122 can be formed by forming the shape and recess features 158 simultaneously. Figure 7 The rectangular cross-section of the pad 122 is shown, Fig.11 The liner 122 is formed to have a shape that requires fewer secondary forming operations or cutting operations.

[0057] Fig.16253 is a schematic diagram showing a system 250 for shaping a product 253, for example, a product formed by a plurality of thermoplastic resin strands, for example as a consolidated filament structure. A distributor 252 is provided to distribute a plurality of molten thermoplastic resin strands. According to an example, the distributor 252 may be provided with an extruder and a die as described above. The strand or product may be shaped by an assembly 254. The assembly 254 may be provided with one or more subassemblies. In one example, the assembly 254 is provided with a single subassembly as described above. In another example, the assembly 254 is provided with any combination of two, three, four or more subassemblies and subassemblies as described above. Each subassembly can be configured as: (i) a first subassembly 256, the first subassembly 256 having a conveyor belt for conveying products, and a plurality of forming tools attached to the conveyor belt to shape the products as the products are conveyed along the conveyor belt, (ii) a second subassembly 258, the second subassembly 258 having a pair of spaced-apart conveyor belts for conveying products between the conveyor belts, and an actuator that cooperates with the pair of conveyor belts to change the spacing between the pair of conveyor belts to shape the products as they are conveyed, (iii) a third subassembly 260, the third subassembly 260 having an actuator array including one or more actuators, each actuator being deployable to contact the product, and a controller configured to control the position of each actuator to contact the product and shape the product as the product moves through the actuator array, or (iv) a fourth subassembly 262, the fourth subassembly 262 including one or more nozzles, the one or more nozzles being positioned to direct a fluid toward the product to shape the product as the product moves through the one or more nozzles. The subassemblies may be arranged in a sequential order relative to the product and / or may be positioned to act on the product simultaneously. Fig.16 A representative and non-limiting schematic arrangement of subassemblies 256, 258, 260, 262 is shown, and other arrangements of subassemblies as described herein are also contemplated. As shown, and according to one non-limiting example, one or more of the subassemblies can be at least partially immersed in a fluid bath 264 to act on and shape the product. Similar to the above, other elements (such as funnels) and additional rollers or traction conveyors can also be provided for use with system 250, and for simplicity, the following are not provided in detail. Fig.16 Other elements and additional rollers or traction conveyor belts are not shown in the schematic diagram.

[0058] Fig.17A method 300 for forming a product (e.g., a solidified filament structure of a modeling) is shown. In various examples, each step in the method 300 can be omitted, added, rearranged into another order, or sequentially or simultaneously performed. In step 302, for example, multiple strands of molten polymer material are distributed from a die. In step 304, force is applied to multiple strands via one or more forming assemblies, thereby multiple strands are shaped into a solidified filament structure of a modeling. The forming assembly can be provided by one or more nozzles, one or more forming conveyor belts and / or one or more actuator assemblies. The forming assembly 304 is shown as having a first forming assembly 304a that first shapes the product, followed by two forming assemblies 304b, 304c that act on the product simultaneously and shape the product. In other examples, the forming assembly 304 can be arranged to act on the product in other orders and shape the product, including sequentially, in parallel, or with any combination thereof. One or more than one forming assembly 304 is by guiding one or more fluid jets from one or more nozzles thereby force is applied on multiple strands, transmits multiple strands along one or more forming conveyor belts thereby force is applied on multiple strands or actuates one or more actuators to contact multiple strands thereby force is applied on multiple strands to make product shaping.In step 306, cool the product in a fluid bath.Note that steps 304 and 306 can occur simultaneously as shown in the figure, so that the product is shaped in a fluid bath when cooling, wherein one or more than one assembly 304 is at least partially immersed in the fluid bath.Or the cooling at step 306 can occur simultaneously with only some in the forming step 304, or occurs after the forming step 304.In step 308, the filament structure of the cutting modeling is to form a component.Then, this component can be used as, for example, a cushion subsequently, and is mounted on the seat component frame.

[0059] Seat assembly, seat or chair can be used herein to generally refer to a component that combines the teachings of one or more embodiments disclosed herein, which may include any combination of the embodiments disclosed herein or the features of the embodiments. Similarly, the terms: seat assembly, seat or chair can refer to the same or similar components. Seat bottom, backrest, base, headrest, headrest or side pillow can be used herein to generally refer to any component, zone or part of a vehicle interior component, seat assembly, vehicle seat or chair. After being distributed through one or more orifices of a template or extrusion die, filaments or strands can be used herein to refer to generally linear polymer units (although they can be looped, fused or combined together to form a mesh structure), which are also used to refer to equivalent parts. Similarly, the terms: product, integral mesh product of shape, consolidated filament structure, filament structure, net, extruded material, cushion blank, thermoplastic cushion, mesh pad, seat cushion or pad can refer to the same or similar parts. The terms funnel and funnel plate can also be used to refer to the same or similar parts. In yet another example, a box, a water tank, a fluid bath, and a fluid chamber may refer to the same or similar parts. In another example, the term traction conveyor and conveyor assembly may refer to the same or similar parts. When describing different preferred embodiments, different terms may be used to refer to the same or similar parts to avoid confusion. These terms may be interchangeable because the various components from the features of the various embodiments may be combined in a manner not explicitly described herein. This does not detract from the fact that some terms may provide inherent details that other interchangeable terms do not include, unless otherwise explicitly stated (e.g., a water tank and a fluid chamber refer to similar interchangeable parts, although in at least one preferred embodiment, the water tank is filled with water or is arranged to be filled with water when the water tank is used, rather than any liquid).

[0060] about Fig.18 Method 1800 is described and illustrated. Method 1800 includes dispensing 1802 a plurality of strands (e.g., 24, 52, 128, and / or 253) of molten polymer material (e.g., linear low density polyethylene (LLDPE)). In some embodiments, filaments or strands may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a web-like structure).

[0061] Method 1800 includes applying 1804 a force on a plurality of strands (e.g., 24, 52, 128, and / or 253) via one or more forming assemblies (e.g., 254, 256, 258, 260, 262) to shape a product (e.g., 32, 59, 94, 98, and / or 253) as the product is conveyed. The one or more forming assemblies may be provided, for example, by a nozzle (e.g., 68 and / or 70), a pair of spaced apart conveyor belts (e.g., 144, 146, 148, 160, 162, 164, and / or 166), and / or an actuator (e.g., 200, 202). In some embodiments, the nozzle (e.g., 68 and / or 70) can be a nozzle having a fluid flow in a single direction or in at least two different directions that are opposite or non-opposite to each other; the nozzle can diverge with an outlet opening larger than the inlet and / or converge with an outlet opening smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath (e.g., 34, 56, 142 and / or 264) or as another fluid and / or gas. In some embodiments, the conveyor belts (e.g., 144, 146, 148, 160, 162, 164, and / or 166) may be provided with actuators (e.g., 168 to change the spacing between the conveyor belts; the conveyor belts may be parallel; one or more conveyor belts may be provided with tracks (e.g., 150, 152) on the conveyor belts, and the tracks may be links or belts; forming tools (e.g., 156) may be connected to the tracks and may be replaceable; the forming tools may form shapes, shapes, and recesses in the product (e.g., 158); and / or there may be four conveyor belts to surround the product. In some embodiments, the actuator (e.g., 202) may be a linear actuator, an electromechanical actuator, a pneumatic actuator, and / or a hydraulic actuator, and may also include an actuator array (e.g., 206), such as a first array, a second array, a third array, and a fourth array surrounding the product, wherein each array at least partially a plurality of actuators (e.g., 206) and a plurality of actuators (e.g., 208) that are disposed on a distal end of the actuator and / or ...In some embodiments, one or more forming assemblies thereby form a plurality of strands into a shaped consolidated filament structure (e.g., 80, 94, 98, 122, 124, and / or 170; a consolidated filament structure, a filament structure, a mesh, an extruded material, a cushion stock, a thermoplastic cushion, a mesh cushion, a seat cushion, and / or a cushion). In some embodiments, a cooling chamber, a fluid bath, a fluid chamber, and / or a heat transfer chamber (e.g., 34, 56, 142, and / or 264) may be provided; wherein the fluid in the fluid bath resists flow, and / or forms a consolidated filament structure, a filament structure, a mesh, an extruded material, a cushion stock, a thermoplastic cushion, a mesh cushion, a seat cushion, or a cushion. In some embodiments, the consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253) may be shaped while the fluid in the fluid bath resists flow, is cooled by the fluid in the fluid bath, and / or forces are applied to the strands while they are in the fluid bath.

[0062] In some embodiments, and for method 1800, the forming assembly (e.g., 254, 304) includes at least one of: one or more nozzles (e.g., 68 and / or 70), one or more forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166), and / or one or more actuator assemblies (e.g., 200). In some embodiments, the nozzle (e.g., 68 and / or 70) can provide fluid flow in a single direction or in at least two different directions that are opposite or not opposite to each other; the nozzle can diverge with an outlet opening larger than the inlet and / or converge with an outlet opening smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath (e.g., 34, 56, 142, and / or 264) or as another fluid / gas. In some embodiments, one or more forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) may be provided by a pair of spaced apart conveyors; an actuator (e.g., 168) may be provided to change the spacing between the pair of conveyors to shape the product as it is conveyed; the conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) may be parallel, and the actuator (e.g., 168) may be a linear actuator; one or more conveyors may be provided with tracks on the conveyors; the tracks may be links or belts; the forming tool (e.g., 156) connected to a track and replaceable; forming tools can form shapes, shapes and recesses in the product (e.g., 158); conveyors (e.g., 144, 146, 148, 160, 162, 164 and / or 166) can be parallel; there can be four conveyors surrounding the product; and / or there can be a cooling chamber, fluid bath, fluid chamber or heat transfer chamber (e.g., 34, 56, 142 and / or 264) in which the fluid in the fluid bath resists flow to form a consolidated filament structure, filament structure, web, extruded material, cushioning blank, thermoplastic cushioning, mesh cushioning, seat cushioning and / or cushioning.In some embodiments, one or more actuators (e.g., 202) may include an array of actuators (e.g., 206); may include up to a first array, a second array, a third array, and a fourth array to surround the product; each array may be at least partially immersed in a fluid bath (e.g., 34, 56, 142, and / or 264); an optional elastic layer (e.g., 212) may be positioned between the actuator head (e.g., 210) and the product; the actuator (e.g., 202) may be a linear actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator; a controller (e.g., 204) may be provided to control the distance the actuator extends to shape the product , controlling the time at which the actuator is deployed to contact the product and / or controlling the actuator based on the feed rate of the product; each actuator (e.g., 202) can have a head (e.g., 210) at the distal end to shape the product; the head can be coated or formed from a rubber material; the head can have different shapes, including curved or flat; the actuator array (e.g., 206) can have rows of straight, curved, or angled actuators (e.g., 207) and contain any number of actuators; and / or each array can also have layers of multiple rows (e.g., 208), such as rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0063] In some embodiments, method 1800 also includes at least one of: directing one or more fluid jets from one or more nozzles (e.g., 68 and / or 70); thereby applying force to multiple strands (e.g., 24, 52, 128 and / or 253), conveying multiple strands (e.g., 24, 52, 128 and / or 253) along one or more forming conveyor belts (e.g., 144, 146, 148, 160, 162, 164 and / or 166), thereby applying force to multiple strands (e.g., 24, 52, 128 and / or 253), and / or actuating one or more actuators (202) to contact multiple strands, thereby applying force to multiple strands (e.g., 24, 52, 128 and / or 253). In some embodiments, the nozzle (e.g., 68 and / or 70) can provide a fluid flow in a single direction or in at least two different directions that are opposite or non-opposite to each other; the nozzle can diverge with an outlet opening that is larger than the inlet and / or converge with an outlet opening that is smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath (e.g., 34, 56, 142 and / or 264) or as another fluid / gas. In some embodiments, the conveyor belt (e.g., 144, 146, 148, 160, 162, 164 and / or 166) can be provided by a pair of spaced-apart conveyor belts, and an actuator (e.g., 168) can be provided to change the spacing between the pair of conveyor belts to shape the product as it is conveyed; the conveyor belts can be parallel; the actuator (e.g., 168) can be a linear actuator; one or more conveyor belts can be provided with tracks (e.g., 150 and / or 152) on the conveyor belt; the track can be a chain link or a belt; the forming tool (e.g., For example, 156) can be connected to a track and can be replaceable; forming tools can form shapes, shapes and recesses in the product (e.g., 158); the conveyors can be parallel; there can be four conveyors surrounding the product; and / or it can include a cooling chamber, a fluid bath, a fluid chamber or a heat transfer chamber (e.g., 34, 56, 142 and / or 264), wherein the fluid in the fluid bath can resist flow, and / or form a consolidated filament structure, filament structure, web, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion and / or cushion.In some embodiments, the actuator (e.g., 202) may include an actuator array (e.g., 206) having up to a first array, a second array, a third array, and a fourth array to surround the product; each array may be at least partially immersed in a fluid bath (e.g., 34, 56, 142, and / or 264); an optional elastic layer (e.g., 212) may be positioned between the actuator head (e.g., 210) and the product; the actuator may be a linear actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator; a controller (e.g., 204) may be provided to control the distance the actuator extends to shape the product, control the actuator portion The actuator can be controlled to contact the product for a certain time and / or based on the feed rate of the product; each actuator (e.g., 202) can have a head (e.g., 210) at a distal end to shape the product; the head can be coated or formed from a rubber material; the head can have different shapes, including curved or flat; the actuator array (e.g., 206) can have rows of straight, curved, or angled actuators (e.g., 207) and contain any number of actuators; and / or each array can also have layers of multiple rows (e.g., 208), such as rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0064] In some embodiments, method 1800 includes moving multiple strands (e.g., 24, 52, 128, and / or 253) through a fluid bath (e.g., 34, 56, 142, and / or 264) (e.g., via a traction conveyor and / or rollers, e.g., 38 and / or 40), applying forces to the multiple strands via one or more forming components (e.g., 254, 304) while the multiple strands are at least partially immersed in the fluid bath (e.g., such that forming occurs within the fluid bath).

[0065] In some embodiments, method 1800 includes cooling a plurality of strands ( 52 and / or 59 ) within a fluid bath (eg, 34 , 56 , 142 , and / or 264 ; a cooling chamber, a fluid chamber, and / or a heat transfer chamber).

[0066] In some embodiments, method 1800 includes cutting a contoured consolidated filament structure (eg, 32, 59, 94, 98, and / or 253). In some embodiments, filaments or strands (e.g., 24, 52, 128 and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused or bonded together to form a mesh structure); and / or consolidated filament structures, filament structures, webs, extruded materials, cushion stock, thermoplastic cushions, mesh cushions, seat cushions or cushions may form vehicle interior components (e.g., seat assemblies, seats or chairs) may refer to the same or similar components; seat bottoms, backs, bases, headrests, headrests or side cushions may be used herein to generally refer to any component, region or portion of a vehicle interior component, seat assembly, vehicle seat or chair; and / or integral nonwoven cushions (e.g., 80, 94, 98, 122, 124 and / or 170) (e.g., cushion stock, thermoplastic cushion, mesh cushion, seat cushion or cushion).

[0067] In some embodiments, method 1800 includes heating (e.g., heating in an extruder (e.g., 16 and / or 134), a rotating screw extruder, and / or an optional heating element) a polymer material (e.g., a linear low density polyethylene (LLDPE)) to a molten state such that it becomes a molten polymer. In some embodiments, method 1800 may include introducing the molten polymer into a die plate (e.g., 18, 20, and / or 136) having a plurality of holes disposed therethrough such that the molten polymer moves through the holes and forms a plurality of strands (e.g., 24, 52, 128, and / or 253) into molten polymer filaments (e.g., from an extruder to a die or die plate). In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure) after being dispensed through one or more orifices of a die plate or extrusion die. In some embodiments, method 1800 includes introducing molten polymer filaments into a bath (e.g., 34, 56, 142, and / or 264) (e.g., a fluid chamber, a cooling chamber, and / or a heat transfer chamber) to cool the molten polymer filaments. In some embodiments, method 1800 includes applying a fluid flow (e.g., via nozzles 68 and / or 70) to the molten polymer filaments via one or more forming components (e.g., 254, 304) to apply force after the molten polymer filaments are introduced into the bath so that the molten polymer filaments are given a desired shape and a consolidated filament structure having a desired shape is formed (e.g., using a nozzle (e.g., 68 and / or 70) wherein the fluid flow is in a single direction or in at least two different directions that are opposite or not opposite to each other; the nozzle can diverge with an outlet opening that is larger than the inlet and / or converge with an outlet opening that is smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath or as another fluid / gas).

[0068] In some embodiments, method 1800 includes a bath (eg, 34, 56, 142, and / or 264) containing a liquid, and the fluid stream (eg, via nozzles 68 and / or 70) includes the liquid. In some embodiments, the nozzle uses the fluid within the fluid bath.

[0069] In some embodiments, applying the fluid stream to the molten polymer filaments includes moving the fluid stream through a nozzle (e.g., 68 and / or 70) before the fluid stream contacts the molten polymer filaments (e.g., using a pump to pump the fluid from a bath or another liquid / gas (including air)).

[0070] In some embodiments, and for use with method 1800 , the nozzle (eg, 68 and / or 70 ) is positioned 10 mm to 15 mm from the surface of the molten polymer filaments.

[0071] In some embodiments, method 1800 includes applying multiple fluid streams (e.g., via nozzles 66 and / or 70) to the molten polymer filaments after the molten polymer filaments are introduced into a bath (e.g., 34, 56, 142, and / or 264). In some embodiments, nozzles 66 and / or 70 can provide fluid flow in a single direction or in at least two different directions that are opposite or not opposite to each other; the nozzles can diverge with an outlet opening that is larger than the inlet and / or converge with an outlet opening that is smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath (e.g., 34, 56, 142, and / or 264) or as another fluid / gas.

[0072] In some embodiments, and using method 1800 , a fluid stream (eg, via nozzles 66 and / or 70 ) is applied to the molten polymer filaments (eg, 24 , 52 , 128 , and / or 253 ) in a single direction.

[0073] In some embodiments, and using method 1800 , fluid streams (eg, 66 and / or 70 ) are applied to molten polymer filaments (eg, 24 , 52 , 128 , and / or 253 ) in at least two different directions (eg, directions opposite or not opposite to each other).

[0074] In some embodiments, method 1800 includes heating a polymer material (e.g., a linear low density polyethylene (LLDPE)) to a molten state to produce a molten polymer material (e.g., heating in extruder 16 and / or 134, a rotary screw extruder, and / or using an optional heating element). In some embodiments, method 1800 includes extruding the molten polymer material to form a plurality of molten polymer filaments as a plurality of strands (e.g., 24, 52, 128, and / or 253). In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure) after being dispensed through one or more orifices of a die plate or extrusion die (e.g., 18, 20, 50, and / or 136). In some embodiments, method 1800 includes cooling a molten polymer material in a fluid bath (e.g., 34, 56, 142, and / or 264; a fluid chamber, a cooling chamber, and / or a heat transfer chamber) to produce a consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, method 1800 includes applying a fluid flow (e.g., via nozzle 68 and / or 70) through one or more forming components to apply a force to the molten polymer filaments in the fluid bath so that the consolidated filament structure has the same desired shape as the shaped consolidated filament structure (e.g., using a nozzle with a fluid flow in a single direction or in at least two different directions that are opposite or not opposite to each other; the nozzle can diverge with an outlet opening larger than the inlet and / or converge with an outlet opening smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath (e.g., 34, 56, 142, and / or 264) or as another fluid / gas).

[0075] In some embodiments, the consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253) is a cushion blank (e.g., 80, 94, 98, 122, 124, and / or 170) for a vehicle seat, and the desired shape includes two side bolsters (e.g., 86 and / or 88) positioned on opposite sides of the cushion blank.

[0076] In some embodiments, method 1800 includes applying multiple fluid streams (e.g., via nozzles 68 and / or 70) to molten polymer filaments (e.g., 24, 52, 128 and / or 253) in at least one direction (e.g., at least two different directions that are opposite or not opposite to each other) in a fluid bath (e.g., 34, 56, 142 and / or 264).

[0077] In some embodiments, at least one of the fluid streams is applied through a nozzle (eg, 68 and / or 70 ) (eg, a converging or diverging nozzle).

[0078] In some embodiments, the nozzles (eg, 68 and / or 70) are diverging nozzles (eg, where diverging is where the outlet opening is larger than the inlet).

[0079] In some embodiments, and for method 1800 , each of the fluid streams is applied to the molten polymer filaments (eg, 24 , 52 , 128 , and / or 253 ) through a corresponding nozzle (eg, 68 and / or 70 ) (eg, a converging or diverging nozzle).

[0080] In some embodiments, at least one of the nozzles (eg, 68 and / or 70) is a converging nozzle (eg, where the convergence is that the outlet opening is smaller than the inlet).

[0081] In some embodiments, the fluid bath (eg, 34, 56, 142, and / or 264) contains a liquid and the fluid stream contains the liquid. In some embodiments, the nozzle uses the fluid within the fluid bath (eg, 34, 56, 142, and / or 264).

[0082] In some embodiments, method 1800 includes heating a polymer material (e.g., a linear low density polyethylene (LLDPE)) to produce a molten polymer material (e.g., by heating in extruder 16 and / or 134, a rotary screw extruder, and / or using an optional heating element). In some embodiments, method 1800 includes forming a plurality of molten polymer filaments as a plurality of strands (e.g., 24, 52, 128, and / or 253) from the molten polymer material. In some embodiments, filaments or strands may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure) after being dispensed through one or more orifices of a die plate or extrusion die. In some embodiments, method 1800 includes cooling the molten polymer material in a fluid bath (e.g., 34, 56, 142, and / or 264; a fluid chamber and / or a heat transfer chamber). In some embodiments, method 1800 includes directing a fluid flow (e.g., via nozzles 68 and / or 70) at a molten polymer material in a fluid bath to apply a force via one or more forming components so that the molten polymer acquires a desired shape (e.g., using nozzles 68 and / or 70 where the fluid flows in a single direction or in at least two different directions that may or may not be opposite to each other; the nozzle may diverge with an outlet opening that is larger than an inlet and / or converge with an outlet opening that is smaller than an inlet; and / or a pump may be used to provide fluid to the nozzle from the fluid bath or as another fluid / gas).

[0083] In some embodiments, method 1800 includes cooling a molten polymer in a fluid bath (e.g., 34, 56, 142, and / or 264) to form a consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253), and directing a fluid stream (e.g., via nozzles 68 and / or 70) at the molten polymer in the fluid bath to impart a desired shape to the consolidated filament structure as a shaped consolidated filament structure. In some embodiments, the technique utilizes a fluid stream from a nozzle in a fluid bath to form.

[0084] In some embodiments, method 1800 includes directing multiple fluid streams (e.g., from nozzles 68 and / or 70, fluid streams in a single direction, or in at least two different directions that are opposite or non-opposite to each other) in at least one direction toward a molten polymer material in a fluid bath (e.g., 34, 56, 142, and / or 264).

[0085] In some embodiments, the consolidated filament structure is a cushion stock for a vehicle seat (e.g., 80, 94, 98, 122, 124, and / or 170), and the desired shape includes two side bolsters (e.g., 86 and / or 88) positioned on opposite sides of the cushion stock. In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure); consolidated filament structures (e.g., 32, 59, 94, 98, and / or 253), filament structures, webs, extruded materials, cushion stock, thermoplastic cushions, mesh cushions, seat cushions, or cushions.

[0086] In some embodiments, the molten polymer material is a molten thermoplastic resin (e.g., linear low density polyethylene (LLDPE)), and the shaped consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253) is a shaped integral mesh product. In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure); consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253), filament structure, web, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion. In some embodiments, method 1800 includes conveying multiple strands (e.g., 24, 52, 128 and / or 253) along at least one forming conveyor (e.g., 144, 146, 148, 160, 162, 164 and / or 166) of one or more forming assemblies while applying force and forming the multiple strands into a shaped, integral mesh product. In some embodiments, method 1800 includes a pair of spaced-apart conveyor belts and an actuator (e.g., 168), the actuator being used to change the spacing between the pair of conveyor belts to shape the product as it is conveyed; the conveyor belts can be parallel and the actuator can be a linear actuator; one or more conveyor belts can have tracks (e.g., 150, 152) on the conveyor belts; the tracks can be links or belts; a forming tool (e.g., 156) can be connected to the tracks and be replaceable; the forming tool can form shapes, shapes, and recesses in the product (e.g., 158); the conveyor belts can be parallel; there can be four conveyor belts surrounding the product; and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) can be provided, wherein the fluid in the fluid bath can resist flow to form a consolidated filament structure, filament structure, mesh, extruded material, gasket blank, thermoplastic gasket, mesh gasket, seat cushion, or cushion.

[0087] In some embodiments, method 1800 includes conveying a plurality of strands (eg, 24, 52, 128, and / or 253) within a plurality of forming conveyors (eg, 144, 146, 148, 160, 162, 164, and / or 166) as a shaped unitary web product.

[0088] In some embodiments, method 1800 includes translating at least one of a plurality of forming conveyor belts (e.g., 144, 146, 148, 160, 162, 164, and / or 166) to change the spacing between the plurality of forming conveyor belts while conveying and shaping a plurality of strands (e.g., 24, 52, 128, and / or 253) (e.g., a pair of spaced-apart conveyor belts and an actuator (e.g., 168) may be used to change the spacing between a pair of conveyor belts to shape a product as it is conveyed; the conveyor belts may be parallel, the actuator may be a linear actuator, and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) may be provided).

[0089] In some embodiments, method 1800 includes shaping a plurality of strands (e.g., 24, 52, 128, and / or 253) using at least one forming tool (e.g., 156) attached to at least one forming conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) (e.g., one or more conveyors may be provided with tracks (e.g., 150 and / or 152 on the conveyor; the tracks may be links or belts; the forming tool may be connected to the tracks and may be replaceable; the forming tool may form shapes, moldings, and recesses in the product (e.g., 158); the conveyors may be parallel; there may be four conveyors surrounding the product; and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber may be provided (e.g., 34, 56, 142, and / or 264)).

[0090] In some embodiments, method 1800 includes resisting the flow of multiple strands (e.g., 24, 52, 128, and / or 253), thereby causing the multiple strands to bend, and the bent strands are cross-linked into an integral nonwoven body (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the fluid in the fluid bath (e.g., 34, 56, 142, and / or 264) resists flow and forms a consolidated filament structure, filament structure, web, extruded material, gasket blank, thermoplastic gasket, mesh gasket, seat cushion, or cushion.

[0091] In some embodiments, method 1800 includes cooling a plurality of strands (e.g., 24, 52, 128, and / or 253) to combine into a shaped overall mesh product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, cooling can be performed in a fluid bath, fluid chamber, and / or heat transfer chamber (e.g., 34, 56, 142, and / or 264).

[0092] In some embodiments, method 1800 includes cooling multiple strands (e.g., 24, 52, 128, and / or 253) while shaping the multiple strands (e.g., in a fluid bath, fluid chamber, and / or heat transfer chamber (e.g., 34, 56, 142, and / or 264)).

[0093] In some embodiments, method 1800 includes cooling a plurality of strands (eg, 24, 52, 128, and / or 253) in a cooling chamber (eg, a fluid bath, fluid chamber, and / or heat transfer chamber (eg, 34, 56, 142, and / or 264)).

[0094] In some embodiments, the molten polymer material is a molten thermoplastic resin (e.g., linear low density polyethylene (LLDPE)), and the shaped consolidated filament structure (e.g., 32, 59, 94, 98, and / or 253) is a shaped integral mesh product. In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure); a consolidated filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, or a cushion. In some embodiments, method 1800 includes actuating one or more actuators (e.g., 202) of one or more forming components to contact multiple strands, thereby applying force and forming the multiple strands into a shaped integral mesh product. In some embodiments, the actuator array (e.g., 206) optionally includes up to a first array, a second array, a third array, and a fourth array to surround the product, wherein each array is at least partially immersed in a fluid bath (e.g., 34, 56, 142, and / or 264); an optional elastic layer (e.g., 212) can be positioned between the actuator head (e.g., 210) and the product; the actuator can be a linear actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator; a controller can be provided to control the distance the actuator extends to shape the product, control the time when the actuator is deployed to contact the product The actuators can be controlled at intervals and / or based on the feed rate of the product; each actuator can have a head (e.g., 210) at the distal end to shape the product; the head can be coated or formed from a rubber material; the head can have different shapes, including curved or flat; the actuator array (e.g., 206) can have a row (e.g., 207) of actuators that are straight, curved, or angled and contain any number of actuators; and / or each array can also have multiple layers of rows (e.g., 208), such as rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0095] In some embodiments, method 1800 includes conveying multiple strands (e.g., 24, 52, 128 and / or 253) through one or more actuators (e.g., 202) (e.g., via traction conveyors 38 and / or 60 and / or rollers 40) as a shaped overall mesh product (e.g., 32, 59, 94, 98 and / or 253).

[0096] In some embodiments, method 1800 includes actuating a first actuator among one or more actuators (e.g., 202) and a second actuator among one or more actuators (e.g., 202) opposite to the first actuator to change the spacing between multiple strands while shaping the multiple strands (e.g., 24, 52, 128 and / or 253).

[0097] In some embodiments, method 1800 includes resisting the flow of multiple strands (e.g., 24, 52, 128, and / or 253) so that the multiple strands are bent, and the bent strands are cross-linked into an integral nonwoven body (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the fluid in the fluid bath (e.g., 34, 56, 142, and / or 264) can resist the flow and / or form a consolidated filament structure, filament structure, web, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion.

[0098] In some embodiments, method 1800 includes cooling multiple strands (e.g., 24, 52, 128 and / or 253) to combine into a shaped integral mesh product (e.g., 32, 59, 94, 98 and / or 253) (e.g., cooling in a fluid in a fluid bath (e.g., 34, 56, 142 and / or 264)).

[0099] In some embodiments, method 1800 includes cooling multiple strands (e.g., 24, 52, 128, and / or 253) while shaping the multiple strands (e.g., by applying a force while the strands are in a fluid bath (e.g., 34, 56, 142, and / or 264)).

[0100] In some embodiments, method 1800 includes cooling a plurality of strands (eg, 24, 52, 128, and / or 253) in a fluid chamber (eg, a fluid bath, cooling chamber, and / or heat transfer chamber; 34, 56, 142, and / or 264).

[0101] In some embodiments, vehicle interior components (e.g., seat assemblies, seats, or chairs) may refer to the same or similar components. Seat bottoms, backrests, bases, headrests, headrests, and / or side bolsters may be used herein to generally refer to any component, region, or portion of a vehicle interior component, seat assembly, vehicle seat, and / or chair) are formed by any of the above techniques, including via method 1800.

[0102] In some embodiments, the vehicle interior component is a cushion (eg, 80 , 94 , 98 , 22 , 124 , and / or 170 ) for a vehicle seat and includes two side bolsters positioned on opposite sides of the cushion.

[0103] In some embodiments, a product is manufactured according to the above techniques, for example, via method 1800 .

[0104] In some embodiments, the shaped consolidated filament structure (eg, 32, 59, 94, 98, and / or 253) forms a product. Method 1800 includes installing the product as a seat cushion on a seat frame.

[0105] In some embodiments, a seat assembly (eg, a seat assembly, a seat, and / or a chair) is manufactured according to the techniques described above, including via method 1800 .

[0106] A product manufactured according to a method is described. The method includes dispensing a plurality of strands of molten thermoplastic resin (e.g., 24, 52, 128, and / or 253). In some embodiments, after being dispensed through one or more orifices of a die plate or extrusion die (e.g., 18, 20, and / or 136), filaments or strands may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a web-like structure).

[0107] The method includes forming a plurality of strands into a shaped, integral mesh product (e.g., a consolidated filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, and / or a cushion) by applying force to the plurality of strands via one or more forming components (e.g., 254, 304), wherein the forming components include at least one of: one or more nozzles (e.g., 68 and / or 70), one or more forming conveyors (e.g., 144, 146 and / or 148), and / or one or more actuator assemblies (e.g., 200, 202). In some embodiments, the nozzle (e.g., 68 and / or 70) can include a fluid jet from a nozzle that is in a single direction, or in at least two different directions that are opposite or non-opposite to each other; the nozzle can diverge with an outlet opening that is larger than the inlet and / or converge with an outlet opening that is smaller than the inlet; and / or a pump can be used to provide fluid to the nozzle from a fluid bath (e.g., 34, 56, 142 and / or 264) or as another fluid / gas. In some embodiments, the forming conveyor (e.g., 144, 146 and / or 148) may include one or more conveyor belts having tracks (e.g., 150 and / or 152) thereon; the tracks may be links or belts; forming tools (e.g., 156) may be connected to the tracks and may be replaceable; the forming tools may form shapes, moldings, and recesses (e.g., 158) in the product; the conveyor belts may be parallel; there may be four conveyor belts surrounding the product; and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) may be provided, or a pair of spaced-apart conveyor belts and an actuator (e.g., 168) may be provided to vary the spacing between the pair of conveyor belts to shape the product as it is conveyed, the conveyor belts may be parallel, the actuator (e.g., 168) may be a linear actuator, and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) may be provided.

[0108] In some embodiments, the method includes shaping the plurality of strands by actuating one or more actuators (e.g., 202) of one or more shaping assemblies to contact the plurality of strands (e.g., 24, 52, 128, and / or 253), thereby shaping the plurality of strands into a shaped integral mesh product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the actuator (e.g., 202) may include an array of actuators (e.g., 206), and may include up to a first array, a second array, a third array, and a fourth array to surround the product, wherein each array is at least partially immersed in a fluid bath; an optional elastic layer (e.g., 212) may be positioned between the actuator head (e.g., 210) and the product; the actuator may be a linear actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator; a controller (e.g., 204) may be provided to control the distance the actuator extends to shape the product, control the actuator deployment to contact the product, and control the distance the actuator extends to contact the product. The actuators can be controlled at the timing of the product and / or based on the feed rate of the product; each actuator can have a head (e.g., 210) at the distal end to shape the product; the head can be coated or formed from a rubber material; the head can have different shapes, including curved or flat; the actuator array (e.g., 206) can have rows of straight, curved, or angled actuators (e.g., 207), and can contain any number of actuators; and / or each array can also have layers of multiple rows (e.g., 208), such as rows stacked on top of each other in the direction of travel, so that the product passes through multiple layers of actuators.

[0109] In some embodiments, the method includes shaping the multiple strands (e.g., 24, 52, 128, and / or 253) by conveying the multiple strands (e.g., 24, 52, 128, and / or 253) through one or more forming conveyor belts (e.g., 144, 146, 148, 160, 162, 164, and / or 166) of one or more forming assemblies to contact the multiple strands, thereby forming the multiple strands into a shaped overall mesh product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the forming conveyor (e.g., 144, 146, 148, 160, 162, 164 and / or 166) can include one or more conveyor belts having tracks (e.g., 150 and / or 152); the tracks can be links or belts; forming tools (e.g., 156) can be connected to the tracks and can be replaceable; the forming tools form shapes, shapes and recesses in the product (e.g., 158); the conveyor belts can be parallel; there can be four conveyor belts surrounding the product; a cooling chamber, fluid bath, fluid chamber or heat transfer chamber (e.g., 34, 56, 142 and / or 264); a pair of spaced apart conveyor belts having an actuator (e.g., 168) to change the spacing between the pair of conveyor belts when conveying the product to shape the product, the conveyor belts can be parallel, the actuator (e.g., 168) can be a linear actuator, and / or a cooling chamber, fluid bath, fluid chamber or heat transfer chamber (e.g., 34, 56, 142 and / or 264).

[0110] In some embodiments, the method includes shaping the plurality of strands (e.g., 24, 52, 128, and / or 253) by directing one or more fluid jets toward the plurality of strands (e.g., 52) through one or more nozzles (e.g., 68 and / or 70) of one or more shaping assemblies to contact the plurality of strands (e.g., 52) to shape the plurality of strands into a shaped, integral web product. In some embodiments, the fluid jets from the nozzles may be disposed in a single direction, or in at least two different directions that may or may not be opposite to each other; the nozzles may diverge with an outlet opening that is larger than an inlet and / or converge with an outlet opening that is smaller than an inlet; and / or a pump may be used to provide fluid to the nozzles from a fluid bath (e.g., 34, 56, 142, and / or 264) or as another fluid / gas.

[0111] In some embodiments, the product (e.g., 24, 52, 128 and / or 253) includes an integral nonwoven pad (e.g., 80, 94, 98, 122, 124 and / or 170; a consolidated filament structure, a filament structure, a web, an extruded material, a pad blank, a thermoplastic pad, a mesh pad, a seat pad and / or a pad).

[0112] A component is described. The component (e.g., 254) includes at least one of: (i) a first subcomponent (e.g., 256), (ii) a second subcomponent (e.g., 258), (iii) a third subcomponent (e.g., 260), and (iv) a fourth subcomponent (e.g., 262).

[0113] (i) A first subassembly (e.g., 256) includes: a conveyor belt (e.g., 144, 146, 148, 160, 162, 164, and / or 166) for conveying products (e.g., consolidated filament structures, filament structures, webs, extruded materials, cushion blanks, thermoplastic cushions, mesh cushions, seat cushions, or cushions); and a plurality of forming tools (e.g., 156) attached to the conveyor belt (e.g., 144, 146, 148, 160, 162, 164, and / or 166) for forming products (e.g., 32, 59, 94, 98, and / or 253) as the products are conveyed along the conveyor belt. In some embodiments, the conveyor belts (e.g., 144, 146, 148, 160, 162, 164 and / or 166) can be, for example, one or more conveyor belts having tracks on the conveyor belt, where the tracks can be links or belts; forming tools (e.g., 156) can be connected to the tracks and be replaceable; where the forming tools can form shapes, shapes, and recesses (e.g., 158) in the product; the conveyor belts can be parallel; there can be four conveyor belts surrounding the product; and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber can be provided.

[0114] (ii) A second subassembly (e.g., 258) includes: a pair of spaced apart conveyor belts (e.g., 164 and / or 166) to convey products (e.g., 32, 59, 94, 98, and / or 253) between the conveyor belts; and an actuator (e.g., 168) that cooperates with the pair of conveyor belts to change the spacing between the pair of conveyor belts to shape the products as they are conveyed. In some embodiments, the pair of spaced apart conveyor belts and the actuator (e.g., 168) can change the spacing between the pair of conveyor belts to shape the products as they are conveyed; the conveyor belts can be parallel, the actuator (e.g., 168) can be a linear actuator; and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) can also be provided.

[0115] (iii) a third subassembly (e.g., 200, 260) includes an actuator array (e.g., 206) and a controller (e.g., 204), the actuator array including one or more actuators (e.g., 202), each actuator being deployable to contact a product (e.g., 32, 59, 94, 98 and / or 253), and the controller being configured to control the position of each actuator to contact and shape the product as the product moves past the actuator array. In some embodiments, the third subassembly can be an array (e.g., 206) of actuators (e.g., 202), and can include up to a first array, a second array, a third array, and a fourth array to surround the product, wherein each array is at least partially immersed in a fluid bath (e.g., 34, 56, 142, and / or 264); an optional elastic layer (e.g., 212) can be positioned between the actuator head (e.g., 210) and the product; the actuator (e.g., 202) can be a linear actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator; a controller (e.g., 204) can be provided to control the distance the actuator extends to shape the product, the time the actuator is deployed to contact the product, and / or the base The actuator can be controlled based on the feed rate of the product; each actuator (e.g., 202) can have a head (e.g., 21) at the distal end to shape the product, and the head can be coated or formed by a rubber material; the head (e.g., 210) can have different shapes, including curved or flat; the actuator array (e.g., 206) can have a row (e.g., 207) of actuators (e.g., 202), a row of actuators is straight, curved or angled, and contains any number of actuators; and / or each array (e.g., 206) can also have multiple layers (e.g., 208) of rows (e.g., 207), such as rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0116] (iv) A fourth subassembly (e.g., 262) includes one or more nozzles (e.g., 68 and / or 70) positioned to direct a fluid toward a product (e.g., 32, 59, 94, 98, and / or 253) to shape the product as it moves past the one or more nozzles. In some embodiments, the nozzles can be used to shape a product (e.g., 32, 59, 94, 98, and / or 253) in a fluid bath (e.g., 34, 56, 142, and / or 264), and the nozzles can have fluid flow in a single direction or in at least two different directions that are opposite or not opposite to each other; the nozzles can diverge with an outlet opening that is larger than the inlet and / or converge with an outlet opening that is smaller than the inlet; and / or a pump can be used to provide fluid to the nozzles from a fluid bath (e.g., 34, 56, 142, and / or 264) or as another fluid / gas.

[0117] In some embodiments, the assembly (e.g., 254) further includes a first subassembly (e.g., 256, one or more conveyor belts (e.g., 144, 146, 148, 160, 162, 164 and / or 166), the conveyor belts having tracks (e.g., 150, 152), and wherein the tracks can be links or belts; forming tools (e.g., 156) can be connected to the tracks and can be replaceable; the forming tools can form shapes, shapes and recesses in the product (e.g., 158); the conveyor belts can be parallel; there can be four conveyor belts surrounding the product; and / or a cooling chamber, fluid bath, fluid chamber or heat transfer chamber (e.g., 34, 56, 142 and / or 264) can also be provided.

[0118] In some embodiments, the assembly (e.g., 254) also includes a second conveyor (e.g., 144, 146, 148, 160, 162, 164 and / or 166) for conveying products (e.g., 32, 59, 94, 98 and / or 253), the second conveyor being spaced apart from the first conveyor to convey products between the first conveyor and the second conveyor (e.g., two conveyors, each of which may have a forming tool 156 on the track 152).

[0119] In some embodiments, the assembly (e.g., 254) further includes a second plurality of forming tools (e.g., 156) attached to a second conveyor (e.g., 144, 146, 148, 160, 162, 164 and / or 166) to shape the products (e.g., 32, 59, 94, 98 and / or 253) as the products are conveyed along the first conveyor and the second conveyor.

[0120] In some embodiments, the assembly (e.g., 254) also includes a cooling chamber (e.g., 34, 56, 142 and / or 264) to cool the product (e.g., 24, 52, 128 and / or 253) as the product is conveyed and formed (e.g., a fluid bath, a fluid chamber, a heat transfer chamber).

[0121] A system (e.g., 250) is described that includes a dispenser (e.g., 252) of a plurality of strands of molten thermoplastic resin (e.g., 24, 52, 128, and / or 253) and an assembly 254 as described above, positioned relative to the dispenser 252 to receive, convey, and shape the plurality of strands.

[0122] In some embodiments, the assembly (e.g., 254) also includes a second subassembly (e.g., 258, 164 and / or 166) (e.g., a pair of spaced-apart conveyor belts and an actuator (e.g., 168) to change the spacing between the pair of conveyor belts as the products are conveyed to shape the products (e.g., 24, 52, 128 and / or 253), the conveyor belts can be parallel, and / or the actuator can be a linear actuator).

[0123] In some embodiments, the assembly (e.g., 250) also includes a cooling chamber (e.g., 34, 56, 142 and / or 264) to cool the product (e.g., 32, 59, 94, 98 and / or 253) as the product is conveyed and formed (e.g., a fluid bath, a fluid chamber and / or a heat transfer chamber).

[0124] A system (e.g., 250) is described. The system (e.g., 250) includes a dispenser (e.g., 252) of a plurality of strands of molten thermoplastic resin (e.g., 24, 52, 128, and / or 253) and an assembly (e.g., 254) positioned relative to the dispenser (e.g., 252) to receive, convey, and shape the plurality of strands.

[0125] In some embodiments, the assembly (e.g., 250) further includes a third subassembly (e.g., 200, 260, and / or an array 206 of actuators 202, which may include up to a first array, a second array, a third array, and a fourth array to surround the product (e.g., 32, 59, 94, 98, and / or 253), wherein each array 106 is at least partially immersed in a fluid bath (e.g., 34, 56, 142, and / or 264); and an optional elastic layer 212 may be positioned between the actuator head 210 and the product). In some embodiments, the actuator 202 may be a linear actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator. In some embodiments, the controller 204 may be configured to control the distance that the actuator 202 extends to shape the product (e.g., 32, 59, 94, 98, and / or 253), control the time that the actuator 202 is deployed to contact the product (e.g., 32, 59, 94, 98, and / or 253), and / or control the actuator 202 based on the feed rate of the product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, each actuator 202 may be provided with a head (e.g., 210) at a distal end to shape the product (e.g., 32, 59, 94, 98, and / or 253), wherein the head 210 may be coated or formed of a rubber material; the head (e.g., 210) may have different shapes, including curved or flat. In some embodiments, the actuator arrays (e.g., 206) can have rows (e.g., 207) of straight, curved, or angled actuators and can include any number of actuators; and / or each array (e.g., 206) can also have multiple layers (e.g., 208) of rows (e.g., 207), such as rows stacked on top of each other in the direction of travel so that the product (e.g., 32, 59, 94, 98, and / or 253) passes through multiple layers of actuators (e.g., 202).

[0126] In some embodiments, the assembly (e.g., 250) further includes a second actuator array (e.g., 206) including one or more second actuators (e.g., 202), each second actuator being deployable to contact a product (e.g., 32, 59, 94, 98, and / or 253), the second actuator array (e.g., 206) being spaced apart from the first actuator array (e.g., 206) such that the product is conveyed therebetween. In some embodiments, the controller (e.g., 204) may be further configured to control the position of each second actuator (e.g., 202) to contact the product (e.g., 32, 59, 94, 98, and / or 253) and shape the product as the product moves past the second actuator array (e.g., an array on a second side, which may be opposite to the first array).

[0127] In some embodiments, the assembly (e.g., 250) further includes a third actuator array (e.g., 206) including one or more third actuators (e.g., 202), each of which is deployable to contact a product (e.g., 32, 59, 94, 98, and / or 253), the third actuator array being spaced apart from the first actuator array and the second actuator array (e.g., 206) such that the product is conveyed therebetween. In some embodiments, the controller 204 may be further configured to control the position of each third actuator 202 to contact a product (e.g., 32, 59, 94, 98, and / or 253) and shape the product as the product moves past the third actuator array (e.g., the array on the third side).

[0128] In some embodiments, the assembly (e.g., 250) further includes a fourth actuator array (e.g., 206), the fourth actuator array (e.g., 206) including one or more fourth actuators (e.g., 202), each fourth actuator being deployable to contact the product (e.g., 32, 59, 94, 98, and / or 253), the fourth actuator array being spaced apart from the first actuator array, the second actuator array, and the third actuator array (e.g., 206) so that the product is conveyed therebetween. In some embodiments, the controller (e.g., 204) can be further configured to control the position of each fourth actuator (e.g., 202) to contact the product (e.g., 32, 59, 94, 98, and / or 253) and shape the product as the product moves past the fourth actuator array (e.g., the array on the fourth side).

[0129] In some embodiments, the first, second, third, and fourth actuator arrays (e.g., 206) are positioned to surround the product (e.g., 32, 59, 94, 98, and / or 253) (e.g., the actuator arrays are on all four sides of the product as it is lowered into the bath).

[0130] In some embodiments, the assembly (e.g., 250) further includes a fluid chamber to cool the product (e.g., 32, 59, 94, 98 and / or 253) while forming the product (e.g., a fluid bath wherein the actuator is at least partially submerged in the bath to contact the product in the bath).

[0131] In some embodiments, the assembly (e.g., 250) further includes a flexible layer (e.g., an elastic layer between the actuator head and the product) located between at least one of the actuators (e.g., 202) and the product (e.g., 32, 59, 94, 98 and / or 253).

[0132] In some embodiments, the controller (eg, 204) is further configured to control a travel distance of at least one of the actuators (eg, 202) to shape the product (eg, by controlling a distance the actuator extends to shape the product).

[0133] In some embodiments, the controller (e.g., 204) is also configured to control the actuation timing of at least one of the actuators (e.g., 202) (e.g., by controlling the time at which the actuator is deployed to contact the product) to shape the product (e.g., 32, 59, 94, 98, and / or 253).

[0134] In some embodiments, the controller (eg, 204) is further configured to receive a signal indicative of a feed rate of the product (eg, 32, 59, 94, 98, and / or 253) and control at least one of the actuators (eg, 202) based on the signal.

[0135] In some embodiments, each actuator (eg, 202 ) comprises a linear actuator.

[0136] In some embodiments, each actuator (e.g., 202) includes a head (e.g., 210) (e.g., the head is located at the distal end of the actuator to contact the product (e.g., 32, 59, 94, 98 and / or 253) and can be coated or formed of a rubber material with different shapes including curved or flat).

[0137] In some embodiments, each head (eg, 210 ) of an actuator (eg, 202 ) comprises rubber.

[0138] In some embodiments, each actuator array (eg, 206) includes a row (eg, 207) of a plurality of actuators (eg, 202) (eg, a row may be straight or curved and contain any number of actuators).

[0139] In some embodiments, each actuator array (eg, 206) includes one or more layers (eg, 208) of rows (eg, 207).

[0140] In some embodiments, the layers (eg, 208) of a row (eg, 207) are positioned to stack in the direction of travel of the product (eg, 32, 59, 94, 98, and / or 253) (eg, the product passes through multiple layers of actuators as it travels).

[0141] A system is described. The system (e.g., 250) includes a dispenser (e.g., 252) of a plurality of strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin and an assembly (e.g., 254) positioned relative to the dispenser (e.g., 252) to receive and shape the plurality of strands (e.g., 24, 52, 128, and / or 253) as the plurality of strands (e.g., 24, 52, 128, and / or 253) pass through the assembly.

[0142] In some embodiments, the assembly (e.g., 254) includes a fourth subassembly (e.g., 262, a nozzle (e.g., 68 and / or 70) having a fluid flow in a single direction and / or in at least two different directions that are opposite or not opposite to each other). In some embodiments, the nozzle (e.g., 68 and / or 70) can diverge with an outlet opening larger than the inlet and / or converge with an outlet opening smaller than the inlet. In some embodiments, a pump can be used to provide fluid from a fluid bath (e.g., 34, 56, 142 and / or 264) or as another fluid / gas to the nozzle (e.g., 68 and / or 70).

[0143] In some embodiments, the nozzles (eg, 68 and / or 70) are positioned to direct fluid flow in a single direction toward the product (eg, 32, 59, 94, 98, and / or 253).

[0144] In some embodiments, nozzles (eg, 68 and / or 70) are positioned to direct fluid flow toward a product (eg, 32, 59, 94, 98, and / or 253) in at least two different directions (eg, opposite or non-opposite directions to each other).

[0145] In some embodiments, at least one of the one or more nozzles (eg, 68 and / or 70) is a diverging nozzle (eg, where diverging is where the outlet opening is larger than the inlet).

[0146] In some embodiments, at least one of the one or more nozzles (eg, 68 and / or 70) is a converging nozzle (eg, where the convergence is that the outlet opening is smaller than the inlet).

[0147] In some embodiments, at least one of the one or more nozzles (eg, 68 and / or 70 ) is a diverging nozzle and at least another of the one or more nozzles (eg, 68 and / or 70 ) is a converging nozzle.

[0148] In some embodiments, the assembly (e.g., 254) also includes a pump fluidly connected to one or more nozzles (e.g., 68 and / or 70) (e.g., the pump can be used to pump fluid from the bath (e.g., 34, 56, 142 and / or 264) or to pump another liquid / gas, including air).

[0149] In some embodiments, a system (e.g., 250) is described. The system (e.g., 250) includes a dispenser (e.g., 252) of a plurality of strands of molten thermoplastic resin (e.g., 24, 52, 128, and / or 253) and an assembly (e.g., 254) as described above, the assembly being positioned relative to the dispenser (e.g., 252) to receive and shape the plurality of strands (e.g., 24, 52, 128, and / or 253) as they pass therethrough.

[0150] In some embodiments, a system (e.g., 250) is described. The system (e.g., 250) includes a dispenser (e.g., 252) of a plurality of strands of molten thermoplastic resin (e.g., 24, 52, 128, and / or 253), a fluid bath (e.g., 34, 56, 142, and / or 264), and an assembly (e.g., 254) as described above, wherein the assembly (e.g., 254) is at least partially immersed in the fluid bath. In some embodiments, after being dispensed through one or more orifices of a die plate or extrusion die (e.g., 16 and / or 134) of an extruder, filaments or strands (e.g., 24, 52, 128, and / or 253) are used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a web-like structure).

[0151] Clause 1. A method, with or without combination with any one or more of the following clauses, comprising dispensing a plurality of strands of molten polymer material and applying forces on the plurality of strands via one or more forming assemblies to shape the plurality of strands into a shaped consolidated filament structure.

[0152] Clause 1A. A method, with or without combination with any one or more of the subsequent clauses, comprising: dispensing a plurality of strands of molten polymer material; and applying a force on the plurality of strands via one or more forming assemblies.

[0153] Clause 2. The method of any preceding or subsequent clause, wherein the forming assembly comprises at least one of: one or more nozzles, one or more forming conveyors, or one or more actuator assemblies.

[0154] Clause 3. A method according to any of the preceding or subsequent clauses, wherein the method further comprises at least one of: directing one or more fluid jets from one or more nozzles to apply force to the multiple strands, conveying the multiple strands along one or more forming conveyor belts to apply force to the multiple strands, or actuating one or more actuators to contact the multiple strands to apply force to the multiple strands.

[0155] Clause 4. The method of any preceding or subsequent clause, further comprising moving the plurality of strands through a fluid bath; and applying a force on the plurality of strands via the one or more shaping assemblies while the plurality of strands are at least partially immersed in the fluid bath.

[0156] Clause 5. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands within a fluid bath.

[0157] Clause 6. The method of any preceding or subsequent clause, further comprising cutting the shaped consolidated filament structure to form at least one of a vehicle interior component or a unitary nonwoven cushion.

[0158] Clause 7. The method according to any of the preceding or subsequent clauses further includes: heating the polymer material to a molten state so that the polymer material becomes a molten polymer; and introducing the molten polymer into a template having a plurality of holes arranged therethrough so that the molten polymer moves through the holes and forms a plurality of strands as molten polymer filaments; and introducing the molten polymer filaments into a bath to cool the molten polymer filaments; and applying a fluid flow to the molten polymer filaments via one or more forming components after the molten polymer filaments are introduced into the bath to apply force so that the molten polymer filaments are given a desired shape and form a consolidated filament structure having the desired shape.

[0159] Clause 8. The method of any preceding or subsequent clause, wherein the bath contains a liquid and the fluid flow comprises the liquid.

[0160] Clause 9. The method of any preceding or subsequent clause, wherein applying the fluid stream to the molten polymer filaments comprises moving the fluid stream through a nozzle before the fluid stream contacts the molten polymer filaments.

[0161] Clause 10. The method of any preceding or subsequent clause, wherein the nozzle is positioned 10 mm to 15 mm from the surface of the molten polymer filaments.

[0162] Clause 11. The method of any preceding or subsequent clause, further comprising applying a plurality of fluid streams to the molten polymer filaments after introducing the molten polymer filaments into the bath.

[0163] Clause 12. The method of any preceding or subsequent clause, wherein the fluid stream is applied to the molten polymer filaments in a single direction.

[0164] Clause 13. The method of any preceding or subsequent clause, wherein the fluid stream is applied to the molten polymer filaments in at least two different directions.

[0165] Clause 14. The method according to any of the preceding or subsequent clauses further includes: heating the polymer material to a molten state to produce a molten polymer material; extruding the molten polymer material to form a plurality of molten polymer filaments as a plurality of strands; cooling the molten polymer material in a fluid bath to produce a consolidated filament structure; and applying a fluid flow to the molten polymer filaments in the fluid bath via one or more forming components to apply force so that the consolidated filament structure has a desired shape as a shaped consolidated filament structure.

[0166] Clause 15. The method of any preceding or subsequent clause, wherein the consolidated filamentary structure is a cushion blank for a vehicle seat, and the desired shape includes two side bolsters positioned on opposite sides of the cushion blank.

[0167] Clause 16. The method of any preceding or subsequent clause, further comprising applying a plurality of fluid streams in at least one direction to the molten polymer filaments in the fluid bath.

[0168] Clause 17. The method of any preceding or subsequent clause, wherein at least one of the fluid streams is applied through a nozzle.

[0169] Clause 18. The method of any preceding or subsequent clause, wherein the nozzle is a diverging nozzle.

[0170] Clause 19. The method of any preceding or subsequent clause, wherein each of the fluid streams is applied to the molten polymer filaments through a respective nozzle.

[0171] Clause 20. The method of any preceding or subsequent clause, wherein at least one of the nozzles is a converging nozzle.

[0172] Clause 21. The method of any preceding or subsequent clause, wherein the fluid bath contains a liquid and the fluid flow comprises the liquid.

[0173] Clause 22. The method according to any of the preceding or subsequent clauses further includes: heating the polymer material to produce a molten polymer material; forming a plurality of molten polymer filaments as a plurality of strands from the molten polymer material; cooling the molten polymer material in a fluid bath; and directing a fluid flow to the molten polymer material in the fluid bath via one or more forming components to apply a force so that the molten polymer acquires a desired shape.

[0174] Clause 23. A method according to any preceding or subsequent clause, wherein the consolidated filament structure is formed by cooling a molten polymer in a fluid bath, and the desired shape is imparted to the consolidated filament structure by directing a fluid flow to the molten polymer in the fluid bath to serve as a shaped consolidated filament structure.

[0175] Clause 24. The method of any preceding or subsequent clause, further comprising directing a plurality of fluid streams in at least one direction at the molten polymer material in the fluid bath.

[0176] Clause 25. The method of any preceding or subsequent clause, wherein the consolidated filamentary structure is a cushion blank for a vehicle seat, and the desired shape includes two side bolsters positioned on opposite sides of the cushion blank.

[0177] Clause 26. A method according to any of the preceding or subsequent clauses, wherein the molten polymer material is a molten thermoplastic resin and the shaped consolidated filament structure is a shaped integral mesh product; wherein the method further comprises: conveying a plurality of strands along at least one forming conveyor belt of one or more forming components while applying force and forming the plurality of strands into a shaped integral mesh product.

[0178] Clause 27. The method of any preceding or subsequent clause, further comprising conveying the plurality of strands within a plurality of forming conveyors into a shaped unitary web product.

[0179] Clause 28. The method of any preceding or subsequent clause, further comprising translating at least one of the plurality of forming conveyor belts to change spacing between the plurality of forming conveyor belts while conveying and forming the plurality of strands.

[0180] Clause 29. The method of any preceding or subsequent clause, further comprising shaping the plurality of strands using at least one forming tool attached to at least one forming conveyor.

[0181] Clause 30. The method of any preceding or subsequent clause, further comprising resisting flow of the plurality of strands, thereby causing the plurality of strands to buckle, the buckled strands crosslinking into a unitary nonwoven body.

[0182] Clause 31. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands to combine into a shaped unitary web product.

[0183] Clause 32. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands while shaping the plurality of strands.

[0184] Clause 33. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands in a cooling chamber.

[0185] Clause 34. A method according to any of the preceding or subsequent clauses, wherein the molten polymer material is a molten thermoplastic resin and the shaped consolidated filament structure is a shaped integral mesh product; wherein the method further comprises: actuating one or more actuators of one or more forming components to contact the plurality of strands, thereby applying force and forming the plurality of strands into a shaped integral mesh product.

[0186] Clause 35. The method of any preceding or subsequent clause, further comprising passing the plurality of strands through one or more actuators to form a shaped unitary mesh product.

[0187] Clause 36. The method of any preceding or subsequent clause further comprises actuating a first actuator of the one or more actuators and a second actuator of the one or more actuators opposite the first actuator to change a spacing between the first actuator and the second actuator when shaping the plurality of strands.

[0188] Clause 37. The method of any preceding or subsequent clause, further comprising resisting flow of the plurality of strands, thereby causing the plurality of strands to buckle, the buckled strands cross-linking into a unitary nonwoven body.

[0189] Clause 38. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands to combine into a shaped unitary web product.

[0190] Clause 39. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands while shaping the plurality of strands.

[0191] Clause 40. The method of any preceding or subsequent clause, further comprising cooling the plurality of strands in the fluid chamber.

[0192] Clause 41. A vehicle interior component formed by a method according to any preceding or subsequent clause.

[0193] Clause 42. The vehicle interior component of Clause 41, wherein the vehicle interior component is a cushion for a vehicle seat and includes two side bolsters positioned on opposite sides of the cushion.

[0194] Clause 43. A product manufactured according to the method of any preceding or subsequent clause.

[0195] Clause 44. The method of any preceding or subsequent clause, wherein the shaped consolidated filament structure forms a product; and wherein the method further comprises mounting the product on a seat frame as a seat pad.

[0196] Clause 45. A seat assembly manufactured according to the method of any preceding or subsequent clause.

[0197] Clause 46. A product manufactured according to a method, with or without combination with any one or more of the subsequent clauses, the method comprising: dispensing a plurality of strands of molten thermoplastic resin; and forming the plurality of strands into a shaped integral mesh product by applying force to the plurality of strands via one or more forming assemblies, wherein the forming assembly comprises at least one of: one or more nozzles, one or more forming conveyors, and / or one or more actuator assemblies.

[0198] Clause 47. The product of any preceding or subsequent clause, wherein the method further comprises shaping the plurality of strands by actuating one or more actuators of the one or more shaping assemblies to contact the plurality of strands, thereby shaping the plurality of strands into a shaped unitary mesh product.

[0199] Clause 48. A product according to any preceding or subsequent clause, wherein the method further comprises shaping the plurality of strands by conveying the plurality of strands through one or more forming conveyors of one or more forming assemblies to contact the plurality of strands, thereby forming the plurality of strands into a shaped unitary mesh product.

[0200] Clause 49. A product according to any preceding or subsequent clause, wherein the method further comprises shaping the plurality of strands by directing one or more fluid jets toward the plurality of strands through one or more nozzles of one or more shaping assemblies to contact the plurality of strands, thereby shaping the plurality of strands into a shaped integral mesh product.

[0201] Clause 50. The product of any preceding or subsequent clause, further comprising an integral nonwoven liner.

[0202] Article 51. A component, in combination with or without any one or more of the subsequent clauses, comprising at least one of: (i) a first subassembly, the first subassembly comprising: a conveyor belt for conveying products, and a plurality of forming tools, the plurality of forming tools attached to the conveyor belt to shape the products as they are conveyed along the conveyor belt; (ii) a second subassembly, the second subassembly comprising: a pair of spaced-apart conveyor belts, the conveyor belts for conveying products between the conveyor belts, and an actuator, the actuator cooperating with the pair of conveyor belts to change the spacing between the pair of conveyor belts to shape the products as they are conveyed; (iii) a third subassembly, the third subassembly comprising: an actuator array, the actuator array comprising one or more actuators, each actuator being deployable to contact the product, and a controller, the controller being configured to control the position of each actuator to contact and shape the product as the product moves past the actuator array; and / or (iv) a fourth subassembly, the fourth subassembly comprising one or more nozzles, the one or more nozzles being positioned to direct a fluid toward the product to shape the product as the product moves past the one or more nozzles.

[0203] Clause 52. A component according to any preceding or subsequent clause, further comprising a first subcomponent.

[0204] Clause 53. The assembly of any preceding or subsequent clause, further comprising a second conveyor belt for conveying products, the second conveyor belt being spaced apart from the first conveyor belt for conveying products between the first conveyor belt and the second conveyor belt.

[0205] Clause 54. The assembly of any preceding or subsequent clause, further comprising a second plurality of forming tools attached to the second conveyor belt to shape the product as it is conveyed along the first and second conveyor belts.

[0206] Clause 55. An assembly as described in any preceding or subsequent clause, further comprising a cooling chamber for cooling the product as it is conveyed and formed.

[0207] Clause 56. A system comprising: a dispenser of a plurality of strands of molten thermoplastic resin; and an assembly according to any preceding or subsequent clause, the assembly positioned relative to the dispenser to receive, convey, and shape the plurality of strands.

[0208] Clause 57. A component according to any preceding or subsequent clause, further comprising a second subcomponent.

[0209] Clause 58. An assembly as described in any preceding or subsequent clause, further comprising a cooling chamber for cooling the product as it is conveyed and formed.

[0210] Clause 59. A system comprising: a dispenser of a plurality of strands of molten thermoplastic resin; and an assembly according to any preceding or subsequent clause, the assembly positioned relative to the dispenser to receive, convey, and shape the plurality of strands.

[0211] Clause 60. A component according to any preceding or subsequent clause, further comprising a third subcomponent.

[0212] Clause 61. A component according to any of the preceding or subsequent clauses, further comprising a second actuator array, the second actuator array comprising one or more second actuators, each second actuator being deployable to contact a product, the second actuator array being spaced apart from the first actuator array so that the product is transferred between the first actuator array and the second actuator array; wherein the controller is further configured to control the position of each second actuator to contact and shape the product as the product moves past the second actuator array.

[0213] Clause 62. A component according to any of the preceding or subsequent clauses, further comprising a third actuator array, the third actuator array comprising one or more third actuators, each third actuator being deployable to contact a product, the third actuator array being spaced apart from the first actuator array and the second actuator array so that the product is transferred between the first actuator array, the second actuator array and the third actuator array; wherein the controller is further configured to control the position of each third actuator to contact and shape the product as the product moves past the third actuator array.

[0214] Clause 63. A component according to any of the preceding or subsequent clauses, further comprising a fourth actuator array, the fourth actuator array comprising one or more fourth actuators, each fourth actuator being deployable to contact a product, the fourth actuator array being spaced apart from the first actuator array, the second actuator array, and the third actuator array so that the product is transferred between the first actuator array, the second actuator array, the third actuator array, and the fourth actuator array; wherein the controller is further configured to control the position of each fourth actuator to contact and shape the product as the product moves past the fourth actuator array.

[0215] Clause 64. The assembly of any preceding or subsequent clause, wherein the first, second, third and fourth actuator arrays are positioned to surround a product.

[0216] Clause 65. An assembly as described in any preceding or subsequent clause, further comprising a fluid chamber for cooling the product as it is formed.

[0217] Clause 66. The assembly of any preceding or subsequent clause, further comprising a flexible layer positioned between at least one of the actuators and the product.

[0218] Clause 67. The assembly of any preceding or subsequent clause, wherein the controller is further configured to control a travel distance of at least one of the actuators to shape the product.

[0219] Clause 68. The assembly of any preceding or subsequent clause, wherein the controller is further configured to control actuation timing of at least one of the actuators to shape the product.

[0220] Clause 69. The assembly of any preceding or subsequent clause, wherein the controller is further configured to receive a signal indicative of a feed rate of the product and to control at least one of the actuators based on the signal.

[0221] Clause 70. An assembly as described in any preceding or subsequent clause, wherein each actuator comprises a linear actuator.

[0222] Clause 71. An assembly as described in any preceding or subsequent clause, wherein each actuator comprises a head.

[0223] Clause 72. An assembly as described in any preceding or subsequent clause, wherein each head of the actuator comprises rubber.

[0224] Clause 73. An assembly as described in any preceding or subsequent clause, wherein each actuator array comprises a row of a plurality of actuators.

[0225] Clause 74. An assembly as described in any preceding or subsequent clause, wherein each actuator array comprises one or more layers of rows.

[0226] Clause 75. An assembly as described in any preceding or subsequent clause, wherein the layers of the row are positioned to be stacked in the direction of travel of the product.

[0227] Clause 76. A system comprising: a dispenser of a plurality of strands of molten thermoplastic resin; and an assembly according to any preceding or subsequent clause, the assembly positioned relative to the dispenser to receive and shape the plurality of strands as the plurality of strands pass through the dispenser.

[0228] Clause 77. A component according to any preceding or subsequent clause, further comprising a fourth subcomponent.

[0229] Clause 78. An assembly as described in any preceding or subsequent clause, wherein the nozzle is positioned to direct the fluid flow in a single direction towards the product.

[0230] Clause 79. An assembly as described in any preceding or subsequent clause, wherein the nozzle is positioned to direct the fluid flow towards the product in at least two different directions.

[0231] Clause 80. The assembly of any preceding or subsequent clause, wherein at least one of the one or more nozzles is a diverging nozzle.

[0232] Clause 81. The assembly of any preceding or subsequent clause, wherein at least one of the one or more nozzles is a converging nozzle.

[0233] Clause 82. The assembly of any preceding or subsequent clause, wherein at least one of the one or more nozzles is a diverging nozzle and at least another of the one or more nozzles is a converging nozzle.

[0234] Clause 83. An assembly as described in any preceding or subsequent clause, further comprising a pump fluidly connected to the one or more nozzles.

[0235] Clause 84. A system comprising: a dispenser of a plurality of strands of molten thermoplastic resin; and an assembly according to any preceding or subsequent clause, the assembly positioned relative to the dispenser to receive and shape the plurality of strands as the plurality of strands pass through the dispenser.

[0236] Clause 85. A system comprising: a dispenser of a plurality of strands of molten thermoplastic resin; a fluid bath; and an assembly according to any of the preceding clauses, wherein the assembly is at least partially immersed in the fluid bath.

[0237] Clause 86. Any combination of any of the preceding clauses 1 to 85.

[0238] Although exemplary embodiments are described above, this does not mean that these embodiments describe all possible forms according to the present disclosure. In this regard, the words used in this specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. In addition, the features of various implementation embodiments can be combined to form additional embodiments according to the present disclosure.

Claims

1. A method comprising: dispensing a plurality of strands of molten polymer material; and A force is applied to the plurality of strands via one or more shaping assemblies.

2. The method according to claim 1, wherein: The forming assembly includes at least one of: one or more nozzles, one or more forming conveyors, or one or more actuator assemblies.

3. The method according to claim 2, wherein: The method also includes at least one of: directing one or more fluid jets from the one or more nozzles to apply force to the multiple strands, conveying the multiple strands along the one or more forming conveyor belts to apply force to the multiple strands, or actuating one or more actuators to contact the multiple strands to apply force to the multiple strands.

4. The method according to any one of claims 1 to 3, further comprising: moving the plurality of strands through a fluid bath; and A force is applied to the plurality of strands via the one or more shaping assemblies while the plurality of strands are at least partially submerged in the fluid bath.

5. The method of claim 4, further comprising cooling the plurality of strands within the fluid bath.

6. The method of any one of claims 1 to 5, further comprising cutting the shaped consolidated filament structure to form at least one of a vehicle interior component or a unitary nonwoven cushion.

7. The method according to any one of claims 1 to 3, further comprising: heating the polymer material to a molten state, so that the polymer material becomes a molten polymer; introducing the molten polymer into a die plate having a plurality of holes disposed therethrough such that the molten polymer moves through the holes and forms the plurality of strands as molten polymer filaments; and introducing the molten polymer filaments into a bath to cool the molten polymer filaments; and A fluid stream is applied to the molten polymer filaments via the one or more forming assemblies after the molten polymer filaments are introduced into the bath to apply a force such that the molten polymer filaments are imparted with a desired shape and a consolidated filament structure having the desired shape is formed.

8. The method according to claim 7, wherein: The bath contains a liquid and the fluid stream includes the liquid.

9. The method according to any one of claims 7 and 8, wherein: Applying the fluid stream to the molten polymer filaments includes moving the fluid stream through a nozzle before the fluid stream contacts the molten polymer filaments.

10. The method according to claim 9, wherein: The nozzle is positioned 10 mm to 15 mm from the surface of the molten polymer filaments.

11. The method of any one of claims 7 to 10, further comprising applying a plurality of the fluid streams to the molten polymer filaments after introducing the molten polymer filaments into the bath.

12. The method according to claim 11, wherein: The fluid stream is applied to the molten polymer filaments in a single direction.

13. The method according to claim 12, wherein: The fluid streams are applied to the molten polymer filaments in at least two different directions.

14. The method according to any one of claims 1 to 3, further comprising: heating a polymer material to a molten state to produce the molten polymer material; extruding the molten polymer material to form a plurality of molten polymer filaments as the plurality of strands; cooling the molten polymer material in a fluid bath to produce a consolidated filament structure; as well as A fluid flow is applied to the molten polymer filaments in the fluid bath via the one or more forming assemblies to apply a force such that the consolidated filament structure has a desired shape as a shaped consolidated filament structure.

15. The method according to claim 14, wherein: The consolidated filament structure is a cushion stock for a vehicle seat, and the desired shape includes two side bolsters positioned on opposite sides of the cushion stock.

16. The method of any one of claims 14 or 15, further comprising applying a plurality of the fluid streams to the molten polymer filaments in the fluid bath in at least one direction.

17. The method according to claim 16, wherein: At least one of the fluid streams is applied through a nozzle.

18. The method according to claim 17, wherein: The nozzle is a diverging nozzle.

19. The method according to any one of claims 14 or 15, wherein: Each of the fluid streams is applied to the molten polymer filaments through a respective nozzle.

20. The method according to claim 19, wherein: At least one of the nozzles is a converging nozzle.

21. The method according to any one of claims 14 to 20, wherein: The fluid bath contains a liquid, and the fluid stream contains the liquid.

22. The method according to any one of claims 1 to 3, further comprising: heating the polymer material to produce a molten polymer material; forming a plurality of molten polymer filaments as the plurality of strands from the molten polymer material; cooling the molten polymer material in a fluid bath; and A fluid stream is directed to the molten polymer material in the fluid bath via the one or more forming assemblies to apply a force such that the molten polymer acquires a desired shape.

23. The method according to claim 22, wherein: A consolidated filament structure is formed by cooling the molten polymer in the fluid bath, and the desired shape is imparted to the consolidated filament structure by directing the fluid stream to the molten polymer in the fluid bath as a shaped consolidated filament structure.

24. The method of any one of claims 22 or 23, further comprising directing a plurality of the fluid streams in at least one direction at the molten polymer material in the fluid bath.

25. The method according to claim 24, wherein: The consolidated filament structure is a cushion stock for a vehicle seat, and the desired shape includes two side bolsters positioned on opposite sides of the cushion stock.

26. The method according to any one of claims 1 to 3, wherein: The molten polymer material is a molten thermoplastic resin, and the shaped consolidated filament structure is a shaped integral web product; Wherein, the method further comprises: The plurality of strands are conveyed along at least one forming conveyor of the one or more forming assemblies while applying force and forming the plurality of strands into the shaped unitary web product.

27. The method of claim 26, further comprising conveying the plurality of strands within a plurality of forming conveyors to form the shaped unitary web product.

28. The method according to claim 27, further comprising: While conveying and shaping the plurality of strands, at least one of the plurality of forming conveyor belts is translated to change the spacing between the plurality of forming conveyor belts.

29. The method of any one of claims 26 to 28, further comprising shaping the plurality of strands using at least one shaping tool attached to the at least one shaping conveyor.

30. The method of any one of claims 26 to 29, further comprising resisting flow of the plurality of strands, thereby causing the plurality of strands to buckle, the buckled strands cross-linking into a unitary nonwoven body.

31. The method of any one of claims 26 to 30, further comprising cooling the plurality of strands to combine into the shaped unitary web product.

32. The method of any one of claims 26 to 31, further comprising cooling the plurality of strands while shaping the plurality of strands.

33. The method of any one of claims 26 to 32, further comprising cooling the plurality of strands in a cooling chamber.

34. The method according to any one of claims 1 to 3, wherein: The molten polymer material is a molten thermoplastic resin, and the shaped consolidated filament structure is a shaped integral web product; Wherein, the method further comprises: One or more actuators of the one or more shaping assemblies are actuated to contact the plurality of strands to apply force and shape the plurality of strands into the shaped unitary mesh product.

35. The method of claim 34, further comprising passing the plurality of strands through the one or more actuators to form the shaped unitary mesh product.

36. The method of claim 35, further comprising actuating a first actuator among the one or more actuators and a second actuator among the one or more actuators opposite to the first actuator to change the spacing between the first actuator and the second actuator when shaping the plurality of strands.

37. The method of any one of claims 34 to 36, further comprising resisting flow of the plurality of strands, thereby causing the plurality of strands to buckle, the buckled strands being cross-linked into a unitary nonwoven body.

38. The method of any one of claims 34 to 37, further comprising cooling the plurality of strands to combine into the shaped unitary web product.

39. The method of any one of claims 34 to 38, further comprising cooling the plurality of strands while shaping the plurality of strands.

40. The method of any one of claims 34 to 39, further comprising cooling the plurality of strands in a fluid chamber.

41. A vehicle interior component formed by the method of any one of claims 1 to 40.

42. The vehicle interior component according to claim 41, wherein: The vehicle interior component is a cushion for a vehicle seat and includes two side bolsters positioned on opposite sides of the cushion.

43. A product manufactured according to the method of any one of claims 1 to 40.

44. The method according to any one of claims 1 to 40, wherein: The shaped consolidated filament structure forms a product; The method further comprises installing the product as a seat pad on a seat frame.

45. A seat component manufactured according to the method of claim 44.

46. ​​A product manufactured according to a method comprising: dispensing a plurality of strands of molten thermoplastic resin; and The plurality of strands are formed into a shaped integral mesh product by applying force to the plurality of strands via one or more forming assemblies, wherein the forming assembly comprises at least one of: one or more nozzles, one or more forming conveyor belts and / or one or more actuator assemblies.

47. The product of claim 46, wherein The method further includes shaping the plurality of strands by actuating the one or more actuators of the one or more shaping assemblies to contact the plurality of strands, thereby shaping the plurality of strands into a shaped unitary mesh product.

48. The product of claim 46, wherein The method further includes shaping the plurality of strands by conveying the plurality of strands through the one or more forming conveyors of the one or more forming assemblies to contact the plurality of strands to form the plurality of strands into a shaped unitary web product.

49. The product, wherein The method further includes shaping the plurality of strands by directing one or more fluid jets contacting the plurality of strands toward the plurality of strands through the one or more nozzles of the one or more shaping assemblies to shape the plurality of strands into a shaped unitary web product.

50. The product of any one of claims 46 to 49 further comprising an integral nonwoven liner.

51. An assembly comprising at least one of: (i) a first subassembly, the first subassembly comprising: a conveyor belt for conveying products, and a plurality of forming tools attached to the conveyor belt to shape the products as they are conveyed along the conveyor belt; (ii) a second subassembly, the second subassembly comprising: a pair of spaced apart conveyor belts for conveying the product between the conveyor belts, and an actuator cooperating with the pair of conveyor belts to change a spacing between the pair of conveyor belts to shape the product as it is conveyed; (iii) a third subassembly, the third subassembly comprising: an actuator array comprising one or more actuators, each actuator being deployable to contact the product, and a controller configured to control the position of each actuator to contact and shape the product as the product moves past the array of actuators; and / or (iv) a fourth subassembly comprising one or more nozzles positioned to direct a fluid toward the product to shape the product as the product moves past the one or more nozzles.

52. The assembly of claim 51 further comprising the first subassembly.

53. The assembly of claim 52, further comprising a second conveyor belt for conveying the product, the second conveyor belt being spaced apart from the first conveyor belt for conveying the product between the first conveyor belt and the second conveyor belt.

54. The assembly of claim 53, further comprising a second plurality of forming tools attached to the second conveyor belt to shape the product as it is conveyed along the first and second conveyor belts.

55. An assembly according to any one of claims 52 to 54, further comprising a cooling chamber for cooling the product as it is conveyed and formed.

56. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; and An assembly according to any one of claims 52 to 55, positioned relative to the dispenser to receive, convey and shape the plurality of strands.

57. The assembly of claim 51 further comprising the second subassembly.

58. The assembly of claim 57 further comprising a cooling chamber for cooling the product as it is conveyed and formed.

59. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; and An assembly as claimed in any one of claims 56 to 58, positioned relative to the dispenser to receive, convey and shape the plurality of strands.

60. The assembly of claim 51 further comprising the third subassembly.

61. The assembly of claim 60, further comprising a second actuator array, the second actuator array comprising one or more second actuators, each second actuator being deployable to contact the product, the second actuator array being spaced apart from the first actuator array such that the product is transferred between the first actuator array and the second actuator array; in, The controller is also configured to control the position of each second actuator to contact and shape the product as the product moves past the second array of actuators.

62. The assembly of claim 61 further comprising a third actuator array comprising one or more third actuators, each third actuator being deployable to contact the product, the third actuator array being spaced apart from the first actuator array and the second actuator array such that the product is transferred between the first actuator array, the second actuator array, and the third actuator array; in, The controller is also configured to control the position of each third actuator to contact and shape the product as the product moves past the third actuator array.

63. The assembly of claim 62, further comprising a fourth actuator array, the fourth actuator array comprising one or more fourth actuators, each fourth actuator being deployable to contact the product, the fourth actuator array being spaced apart from the first actuator array, the second actuator array, and the third actuator array such that the product is transferred between the first actuator array, the second actuator array, the third actuator array, and the fourth actuator array; in, The controller is also configured to control the position of each fourth actuator to contact and shape the product as the product moves past the fourth actuator array.

64. The assembly of claim 63, wherein: The first actuator array, the second actuator array, the third actuator array, and the fourth actuator array are positioned to surround the product.

65. An assembly according to any one of claims 60 to 64, further comprising a fluid chamber for cooling the product as it is formed.

66. An assembly according to any one of claims 60 to 65, further comprising a flexible layer positioned between at least one of the actuators and the product.

67. An assembly according to any one of claims 60 to 66, wherein The controller is also configured to control a travel distance of at least one of the actuators to shape the product.

68. An assembly according to any one of claims 60 to 67, wherein The controller is also configured to control an actuation time of at least one of the actuators to shape the product.

69. An assembly according to any one of claims 60 to 68, wherein The controller is also configured to receive a signal indicative of a feed rate of the product and to control at least one of the actuators based on the signal.

70. An assembly according to any one of claims 60 to 69, wherein Each actuator comprises a linear actuator.

71. An assembly according to any one of claims 60 to 70, wherein Each actuator includes a head.

72. An assembly according to any one of claims 71, wherein Each head of the actuator includes rubber.

73. An assembly according to any one of claims 60 to 72, wherein Each actuator array includes a row of a plurality of actuators.

74. An assembly according to any one of claims 60 to 73, wherein Each actuator array includes one or more layers of rows.

75. The assembly of claim 74, wherein: The layers of the rows are positioned to be stacked in the direction of travel of the product.

76. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; and An assembly according to any one of claims 60 to 75, said assembly being positioned relative to said dispenser to receive and shape said plurality of strands as said plurality of strands pass through said dispenser.

77. The assembly of claim 51 further comprising the fourth subassembly.

78. The assembly of claim 77, wherein: The nozzles are positioned to direct fluid flow in a single direction towards the product.

79. The assembly of claim 77, wherein: The nozzle is positioned to direct fluid flow toward the product in at least two different directions.

80. An assembly according to any one of claims 77 to 79, wherein At least one of the one or more nozzles is a diverging nozzle.

81. An assembly according to any one of claims 77 to 79, wherein At least one of the one or more nozzles is a converging nozzle.

82. An assembly according to any one of claims 77 to 79, wherein At least one of the one or more nozzles is a diverging nozzle, and at least another of the one or more nozzles is a converging nozzle.

83. The assembly of any one of claims 77 to 81 further comprising a pump fluidly connected to the one or more nozzles.

84. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; and An assembly according to any one of claims 77 to 83, said assembly being positioned relative to said dispenser to receive and shape said plurality of strands as said plurality of strands pass through said dispenser.

85. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; fluid bath; and The assembly of claim 51, wherein the assembly is at least partially immersed in the fluid bath.

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