System and method for forming net structure

Abstract

A system and method of forming a mesh structure. The filament mesh structure is placed in the cavity of the mold assembly. A liquid above a first temperature threshold is added to the cavity, thereby softening the filament mesh structure and conforming the shape of the filament mesh structure to the forming surface of the mold assembly. The filament mesh structure is cooled in the mold assembly to set a shape.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 510,793, filed on June 28, 2023, the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] Various embodiments are directed to a system and method for forming a mesh structure, such as a pad. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1 is a perspective view of an example of a seat assembly including a filament mesh structure.

[0005] Figure 2 is a perspective view of an example of a cushion for a seat component that is a filament mesh structure.

[0006] Figure 3 is a schematic diagram of an example of a manufacturing system for manufacturing a filament mesh structure.

[0007] Figure 4 is an exploded view of an example of a die assembly and a filament web prior to being formed in the die assembly.

[0008] Figure 5 is a flow chart of an example of a method of forming a filament network structure.

[0009] Figure 6 and Figure 7 A first example of adding heated liquid to a cavity of a mold assembly according to the method is shown.

[0010] Figure 8 and Fig. 9 A second example of adding heated liquid to the cavity of a mold assembly according to the method is shown.

[0011] Fig.10 and Fig.11 A third example of adding heated liquid to the cavity of a mold assembly according to the method is shown.

[0012] Fig.12 and Fig.13 A first example of cooling a filament web according to the method is shown.

[0013] Fig.14 and Fig.15 A second example of cooling a filament web according to the method is shown.

[0014] Fig.16 and Fig.17 A third example of cooling a filament web according to the method is shown.

[0015] Fig.18 and Fig.19 A fourth example of cooling a filament web according to the method is shown. Detailed Description

[0017] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the present invention, which may be embodied in various forms and alternative forms. 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 present invention in various ways.

[0018] 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.

[0019] It should be understood that the disclosed embodiments are merely exemplary, and that various 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.

[0020] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed fashion), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0021] 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.

[0022] The terms used in the description of the various embodiments described herein are only used 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 also include plural forms, 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.

[0023] 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.

[0024] refer to Figure 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly (e.g., for land vehicles, such as cars, trucks, buses, etc.), or for non-land vehicles (such as aircraft or ships). For example, the seat assembly 10 for land vehicles can be shaped and sized to be used as a front driver or passenger seat, a second, third or other rear seat, and can include a bench seat, a bucket seat or other seat styles. In addition, the seat assembly 10 can be a non-stowable seat or a stowable seat, which can be folded and can be stowed in a cavity in the vehicle floor. In addition, the seat assembly 10 can be configured to be used in non-vehicle applications, such as furniture.

[0025] exist Figure 1 In the illustrated configuration, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool.

[0026] The seat bottom 20 is configured to receive a seated occupant and support the pelvis and thighs of the seat occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0027] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In some configurations, the seat bottom frame 30 includes a panel, a seat pan, a suspension pad, or a suspension wire on which the cushion 32 is disposed.

[0028] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat bottom frame 30. The cushion 32 and associated manufacturing methods will be discussed in more detail below.

[0029] The decorative cover 34 covers at least a portion of the cushion 32. In addition, the decorative cover 34 provides one or more visible outer surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can be placed on the decorative cover 34. The decorative cover 34 is made of any suitable material or materials (such as fabric, leather, artificial leather, vinyl or a combination thereof). The decorative cover 34 may include a plurality of decorative panels assembled in any suitable manner, such as by fusing or stitching. The decorative cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the decorative cover 34 may include decorative attachment features that are attached to the seat bottom frame 30, the cushion 32, or both to inhibit the removal of the decorative cover 34 and help the decorative cover 34 conform to the contours of the seat bottom frame 30, the cushion 32, or both.

[0030] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and adjacent to the rear side of the seat bottom 20. The seat back 22 extends in a generally upward direction away from the seat bottom 20. In some configurations, the seat back 22 is mounted to the seat bottom 20 and may pivot relative to the seat bottom 20. In other configurations, the seat back 22 is not mounted to the seat bottom 20. For example, a vehicle seat back may be mounted to a vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a decorative cover 44, and an optional headrest 46.

[0031] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In some configurations, the seat back frame 40 includes a panel, a base, a suspension pad, or a suspension wire on which the cushion 42 is disposed. It is also contemplated that the seat back frame 40 can be integrally formed with the seat bottom frame 30.

[0032] A cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or separate from the cushion 32 of the seat bottom 20. The cushion 42 and associated manufacturing methods will be discussed in greater detail below.

[0033] The decorative cover 44 covers at least a portion of the cushion 42. In addition, the decorative cover 44 provides one or more visible outer surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can be placed on the decorative cover 44. The decorative cover 44 is made of any suitable material or materials (e.g., fabric, leather, artificial leather, vinyl, or a combination thereof). The decorative cover 44 may include a plurality of decorative panels assembled in any suitable manner, such as by fusing or stitching. The decorative cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the decorative cover 44 may include decorative attachment features that are attached to the seat back frame 40, the cushion 42, or both to inhibit the removal of the decorative cover 44 and help the decorative cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both.

[0034] A headrest 46, if provided, is configured to support the head of a seat occupant. The headrest 46 is disposed on a top portion of the seat back 22, or at an end of the seat back 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be integrally formed with the seat back 22.

[0035] refer to Figure 2 , an example of a cushion 50 is shown. For ease of reference, the cushion is generally indicated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 is applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0036] The pad 50 is a non-foam component or includes at least one non-foam component. The non-foam component is mainly referred to as a mesh member or a filament mesh structure, but may also be referred to as a twisted member, an annular member, a tangled structure, a mesh structure, a twisted net, an annular net, an entangled net or a mesh pad. Figure 2, the cushion 50 is described as a non-foam component that does not include a foam component or foam material (e.g., urethane or polyurethane foam); however, it is contemplated that the cushion 50 may include a foam component or foam material in addition to the non-foam component to provide additional cushioning or partial cushioning to the seat occupant. For example, the foam material may be disposed between the cushion 50 and a trim cover (e.g., trim cover 34, 44) disposed on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam material provided by the cushion 50 or removing foam material from the cushion 50 can reduce weight and can improve support and comfort for the seat occupant. In addition, removing the foam material can facilitate recycling of the cushion 50.

[0037] The pad 50 is described below primarily in the context of the pad 50, which is a non-foam component that does not include a foam material. In this case, the pad 50 is made of filaments of a polymer material that are randomly bent, curled, or looped and bonded together, as will be discussed in more detail below. The filaments are directly bonded to one another, rather than indirectly bonded with a resin or other intermediate material.

[0038] Long filament can also be referred to as strand or line, is made of any suitable one material or multiple materials.In some configurations, long filament is made of polymer material or thermoplastic material, and polymer material or thermoplastic material are for example based on polyamide, based on polyester, based on polyimide, based on polyolefin (for example, based on polypropylene, based on polyethylene etc.), based on thermoplastic resin of polystyrene or its combination.As an example, long filament based on polyethylene can be made of linear low density polyethylene (LLPDE).Different from foam material, long filament material can be recyclable, or more easily recyclable than foam material.Also envision that long filament can comprise reinforcing fiber, and reinforcing fiber may not be made of thermoplastic material.

[0039] In some configurations, the filament can be a monofilament made of a single material. In some configurations, the filament is made of multiple materials. For example, the filament made of multiple materials can include a core made of a first thermoplastic material and a sheath around the core and made of a second thermoplastic material that is different from the first thermoplastic material. It is envisioned that the pad 50 can include a combination of monofilaments and filaments, and the filament is made of multiple materials and is not a monofilament.

[0040] The filaments are randomly bent, looped, curled or entangled and can be bonded together where one filament touches another filament, thereby producing a lightweight, breathable pad (e.g., pad 32 and / or 42) or a mesh structure with openings or gaps between the filaments. Examples of methods for making a mesh pad or mesh structure are disclosed in U.S. Patent Application No. 17 / 555,875, which is hereby incorporated by reference in its entirety. Figure 3Also shown is an example of a manufacturing system 60 for making a cushion or filament web structure. In this example, the manufacturing system 60 includes a hopper 70, an extruder 72, a hopper 74, a cooling tank 76, and a material handling subsystem 78.

[0041] refer to Figure 3 , a container or hopper 70 holds a raw material of material to be extruded, such as solid beads, flakes, granules, pellets or powder made of the material. The hopper 70 provides the raw material of material to the extruder 72.

[0042] Extruder 72 melts the raw material and extrude the raw material into filaments 52. Extruder 72 can have any suitable configuration. In some configurations, extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material to pass through the barrel and helps heat the material due to the friction generated when the screw rotates. The material leaves the barrel under pressure and in a molten state and is transported to the die 80 of the extruder 72.

[0043] The die 80 (also referred to as a die plate or extrusion die) has a plurality of through holes or openings forming filaments, through which the molten material passes. A single filament 52 is extruded from each through hole. The filament 52 falls downward from the die 80 into the funnel 74 under gravity.

[0044] Funnel 74 merges or groups filaments 52 into a more compact arrangement, wherein filaments 52 are bent, curled or looped, and filaments 52 contact and are bonded to at least one other filament 52. Funnel 74 has a funnel inlet and a funnel outlet smaller than the funnel inlet. Individually separated filaments enter the funnel inlet. When filaments 52 accumulate, filaments 122 are bent, curled or looped and move in contact. Filaments 52 move toward the funnel outlet through funnel 74. When filaments move toward the funnel outlet, some filaments can slide along funnel 74 or the intermediate sheet material arranged on funnel 74. Each member in a group of filaments 52 can be bonded to at least one other member in the group of filaments 52. The bond between filaments 52 is formed at the contact point, and the opening or gap between filaments 52 exists in other positions where one filament 52 does not contact or is bonded to another filament 52. The filaments 52 wound and bonded pass through the funnel outlet of funnel 74 and enter cooling tank 76. For ease of reference, the combined filaments are referred to as a mesh member or filament mesh structure 90 .

[0045] Cooling tank 76 holds liquid, for example water or water and the mixture of another fluid.Liquid in cooling tank 76 helps to support the long filament 52 of winding and combining, further compacts or consolidates into the arrangement of less opening or less holes to limit long filament 52, and keeps the desired porosity and the density of long filament network structure 90.Therefore, liquid provides some buoyancy or resistance, and these buoyancy or resistance can cause the extra bending, curling or looping of the long filament 52 in adjacent liquid surface or funnel 74, to further build long filament network structure 90.When long filament 52 is in liquid, liquid also cools down long filament 52.For example, liquid cools down long filament from outside to solidify long filament and prevents long filament 52 from combining in additional position.At this moment, long filament 52 is relatively hard and no longer in plastic state, therefore keeps shape usually, and can not be plasticized or reshaped when not heated.

[0046] The material handling subsystem 78 transports the filament mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyor belts that help move the filament mesh structure 90 through the liquid and out of the liquid. In some configurations, a traction conveyor 92 is provided in the cooling tank 76 to help pull the filament mesh structure 90 out of the funnel 74 and to counteract the buoyancy of the filaments 52.

[0047] Other rollers (e.g., rollers 94) keep the filament mesh structure 90 immersed in the liquid and guide the filament mesh structure 90 through the cooling tank 76. For example, rollers 94 can guide the filament mesh structure 90 to a conveyor belt 96 and a shaker table 98 arranged outside the cooling tank 76. The shaker table 98 vibrates the filament mesh structure 90 while the filament mesh structure 90 is on the conveyor belt 96 to remove liquid. Alternatively or additionally, the filament mesh structure 90 can be squeezed to remove liquid, air can be blown to the filament mesh structure 90 to help remove liquid from the filament mesh structure 90, or both. It is also contemplated that the filament mesh structure 90 can also be allowed to drip dry, or dry in ambient air.

[0048] The above-mentioned manufacturing system 60 is a continuous flow process, in which the filament mesh structure 90 is formed into a continuous structure when the filament extrusion is not interrupted. After leaving the cooling tank 76, further processing of the filament mesh structure 90 is provided to cut the filament mesh structure 90 into individual sheets or billets for individual pads. This processing is performed by a cutting system of the manufacturing system 60. The cutting system can be of any suitable type. For example, the cutting system can use a blade, a knife, a hot knife, a saw, a fluid jet, etc. to cut the filaments 52 of the filament mesh structure 90 into billets. The cutting system can be used to shape or contour the billet. It is also contemplated that the billet can be further shaped or contoured using other manufacturing processes, such as molding of the entire billet or a portion thereof. In Figure 4An example of a sheet or blank of filament mesh structure 90 prior to formation is shown in the middle.

[0049] refer to Figure 4 , an example of a mold assembly 100 is shown. The mold assembly 100 may be part of a molding subsystem of the manufacturing system 60. The mold assembly 100 includes a first mold 102 and a second mold 104. The first mold 102 and the second mold 104 cooperate to define a cavity 106 between the first mold 102 and the second mold 104. The cavity 106 is Figures 7 to 19 The odd-numbered drawings in the drawings are shown with hidden lines.

[0050] The first mold 102 has a first forming surface 110 facing the filament mesh structure 90. The first forming surface 110 defines a portion of the cavity 106 and is configured to contact the filament mesh structure 90 and shape the filament mesh structure 90, as will be discussed in more detail below. More than one hole 112 is provided in the first mold 102 and extends from the first forming surface 110. In some configurations, the hole 112 fluid is connected to the surrounding environment. The hole 112 allows gas to leave the cavity 106, allows liquid to enter the cavity 106, or both, as will be discussed in more detail below. In some configurations, some or all of the holes 112 allow gas to leave the mold assembly 100, allow liquid to enter the mold assembly 100, or both.

[0051] The second mold 104 has a second forming surface 120 facing the filament mesh structure 90. The second forming surface 120 defines a portion of the cavity 106 and is configured to contact the filament mesh structure 90 and shape the filament mesh structure 90, as will be discussed in more detail below. More than one hole 122 is provided in the second mold 104 and extends from the second forming surface 120. In some configurations, the hole 122 fluid is connected to the surrounding environment. The hole 122 allows gas to leave the cavity 106, allows liquid to enter the cavity 106, or both, as will be discussed in more detail below. In some configurations, some or all of the holes 122 allow gas to leave the mold assembly 100, allow liquid to enter the mold assembly 100, or both.

[0052] In some configurations, the apertures 112, 122 can be selectively fluidly connected to the surrounding environment or to a fluid source external to the mold assembly 100. For example, one or more valves can be associated with the apertures 112, 122 and can be opened to allow fluid to enter the cavity 106 or to leave the cavity 106. Thus, fluid can be retained in the cavity 106 by closing one or more valves, and fluid can be allowed to leave the cavity 106 by opening one or more valves.

[0053] The first forming surface 110 and the second forming surface 120 are shaped to mold or form a blank of the filament mesh structure 90. For example, the first forming surface 110 and the second forming surface 120 are shaped to form various contours, features, or shapes in the blank of the filament mesh structure 90, such as planar shapes, non-planar shapes (e.g., concave, convex, or other complex shapes); channels, grooves, protrusions, curves, chamfers, stepped corners, etc. The cavity 106 can be sized to have a smaller size or volume than the blank of the filament mesh structure 90, so that when the mold assembly 100 is closed (e.g., when the first mold 102 and the second mold 104 are engaged or mated along corresponding mating surfaces, the corresponding mating surfaces extend around or around the corresponding forming surfaces), the mold assembly 100 compresses the blank of the filament mesh structure 90.

[0054] refer to Figure 5 , a flow chart of a method for forming a filament mesh structure 90 is shown. The method can be performed using a manufacturing system 60. The method steps are described below in the context of molding and forming a blank or sheet of a filament mesh structure 90 into a desired configuration or shape. Therefore, the method steps are described starting with a sheet of filament mesh structure 90 that has been cooled and removed from a cooling tank 76 and cut into desired sizes.

[0055] At block 200, a sheet of filament web structure 90 is placed in the cavity 106 of the mold assembly 100. The sheet of filament web structure 90 is placed in the cavity 106 of the mold assembly 100 when the mold assembly 100 is open. The mold assembly 100 is opened by moving at least one of the first mold 102 and the second mold 104 in a manner that allows access to the cavity 106. For example, the first mold 102 can be disposed above the second mold 104 and can be lifted or pivoted away from the second mold 104 to provide a gap between the first mold 102 and the second mold 104 that is sufficient to allow the sheet of filament web structure 90 to be placed in the cavity 106. The sheet of filament web structure 90 can be aligned with the first forming surface 110 and the second forming surface 120, thereby allowing the filament web structure 90 to engage or contact the first forming surface 110 and the second forming surface 120 when the mold assembly 100 is closed.

[0056] At block 202, the mold assembly 100 is closed. The mold assembly 100 is closed by moving at least one of the first mold 102 and the second mold 104 so that the first mold 102 and the second mold 104 engage or mate with each other and cooperate to enclose or define the cavity 106. When the mold assembly 100 is closed, the filament web structure 90 is positioned in the cavity 106 between the first mold 102 and the second mold 104, and more specifically, between the first forming surface 110 and the second forming surface 120.

[0057] In some configurations, the mold assembly 100 is disposed outside of a tank 210 that receives a liquid 212 that aids in the softening and forming of the filamentary network structure 90 when a sheet of the filamentary network structure 90 is placed in the cavity 106 . Figure 7 An example of a tank 210 and a liquid 212 is shown, with the tank 210 cut away to show its contents. The mold assembly 100 may not be disposed in the tank 210 when the mold assembly 100 is opened and closed. The tank 210 is different from the cooling tank 76 discussed previously. In such a configuration, multiple mold assemblies may be employed, wherein one mold assembly 100 may be used to receive a sheet of filament mesh 90 while another mold assembly 100 having a sheet of filament mesh 90 is undergoing a forming operation (e.g., being heated or cooled), which may help increase production.

[0058] In some configurations, the mold assembly 100 is at least partially disposed in the tank 210 when the sheet of filament mesh structure 90 is placed in the cavity 106. For example, the first mold 102, the second mold 104, or both can be at least partially disposed in the tank 210 when the sheet of filament mesh structure 90 is placed in the cavity 106. Figure 7 In the example shown, the first mold 102 is disposed above the second mold 104. In this configuration, the second mold 104 can be disposed in the tank 210 when the sheet of filament mesh structure 90 is placed in the cavity 106. The first mold 102 can then be lowered into the tank 210 and positioned to engage and cooperate with the second mold 104. As another example, the first mold 102 can be pivotally mounted to the second mold 104 disposed in the tank 210. In this configuration, the first mold 102 can be disposed outside, partially disposed in, or completely disposed in the tank 210 when the mold assembly 100 is open, and the first mold 102 can be partially or completely disposed in the tank 210 when the mold assembly 100 is closed. Disposing at least a portion of the mold assembly 100 in the tank 210 can reduce or avoid material handling associated with moving the mold assembly 100 into or out of the tank 210.

[0059] At block 204, liquid 212 is added to the cavity 106 of the mold assembly 100. The liquid is added to the cavity 106 after the sheet of filament mesh structure 90 is placed in the cavity 106. The liquid 212 can be of any suitable type. For example, the liquid 212 can be water or a mixture of water and one or more other liquids.

[0060] Liquid 212 is provided to cavity 106 at a temperature higher than a first temperature threshold, which is sufficient to heat filaments 52 to allow filaments 52 of filament mesh structure 90 to be reformed or reshaped. More specifically, the heat energy provided by liquid 212 heats filaments 52 to a temperature that allows filament material to be remolded or reformed into a different shape by a compressive force, which is applied by mold assembly 100 to filament mesh structure 90 therein. In this way, liquid 212 softens filament mesh structure 90 in cavity 106 so that the shape of filament mesh structure 90 conforms to a forming surface, such as first forming surface 110, second forming surface 120 or both. The heat energy provided by liquid 212 softens or plasticizes filaments 52 to make filaments 52 compliant without melting filaments 52. As used herein, the term "compliant" means that the filament material is in a state (e.g., material is at a certain temperature) in which its shape can be permanently changed in mold assembly 100. The liquid 212 is provided in a manner to keep the temperature of the filaments 52 below the melting temperature of the filament material. For example, the filaments 52 can be heated by the liquid 212 to a temperature 10°C to 70°C lower than the melting temperature of the thermoplastic material. Thus, the filaments 52 are heated in such a manner that it is sufficient to allow the filaments 52 to be plastically molded or reshaped, but not sufficient to cause new bonds to be formed between one filament 52 and another filament 52 or between the filament and itself.

[0061] The first temperature threshold may vary based on the filament material employed. For example, when the filament 52 is made of linear low density polyethylene (LLPDE), the liquid 212 may be heated to a temperature of 80° C. to 100° C. The temperature may be monitored or determined using a temperature sensor, such as a thermocouple, a thermistor, a resistance temperature sensor, a semiconductor-based temperature sensor, or the like.

[0062] Liquid 212 may be added to cavity 106 in a variety of ways, Figure 6-Figure 11 Examples of these methods are best illustrated. In some configurations, for example Figure 6-Figure 9 In the configuration shown, when the mold assembly 100 is disposed in the tank 210, the liquid 212 is added to the cavity 106. In other configurations, for example Fig.10 and Fig.11 In the illustrated configuration, adding the liquid 212 includes filling the cavity 106 with the liquid 212 without using the tank 210 .

[0063] refer to Figure 6 and Figure 7In some embodiments, the mold assembly 100 is placed in a tank 210 containing a liquid 212. In other words, the tank 210 contains the liquid 212 before the mold assembly 100 is placed in the tank 210. Providing the liquid in the tank 210 before the mold assembly 100 is placed in the tank 210 can reduce the cycle time compared to placing the mold assembly 100 in the tank 210 and then fully filling the tank 210 with the liquid. In this way, the mold assembly 100 is placed in the tank 210 after the filament web structure 90 is placed in the cavity 106. The mold assembly 100 is placed in the tank 210 when the mold assembly 100 is closed. The mold assembly 100 can be placed in the tank 210 in any suitable manner. For example, the mold assembly 100 can be lowered into the tank 210 with a hoist or a crane, the mold assembly 100 can be placed on a platform that is lowered into the tank 210, and the like.

[0064] Placing the mold assembly 100 in the tank 210 containing the liquid 212 allows the liquid 212 to enter the cavity 106. The liquid 212 enters the various openings of the mold assembly 100 and flows into the cavity 106 through one or more holes 112, 122. As the liquid 212 enters the cavity 106, air is exhausted from the cavity 106 through the various openings or holes 112, 122. For example, as the mold assembly 100 is lowered into the liquid 212, the liquid 212 may enter the openings and holes 122 of the second mold 104. As the mold assembly 100 is lowered into the liquid 212, air exits the cavity 106 through the holes 112 in the first mold 102, the holes 122 in the second mold 104, or both. The mold assembly 100 is partially or completely submerged in the liquid 212. For example, mold assembly 100 may be positioned within liquid 212 such that cavity 106 is positioned below top surface 214 of liquid 212 , thereby allowing liquid 212 to fill cavity 106 .

[0065] As the liquid 212 fills the cavity 106, the liquid 212 passes through the gaps in the filament mesh structure 90 in the cavity 106. In this way, the liquid 212 can be distributed in a generally uniform manner throughout the thickness of the filament mesh structure 90, which can help provide generally uniform heating to the filaments 52 of the filament mesh structure 90.

[0066] refer to Figure 8 and Fig. 9In some embodiments, after the mold assembly 100 is placed in the tank 210, the liquid 212 is added to the tank 210. For example, the tank 210 can be empty, or can contain a sufficiently low level of liquid 212 that the liquid 212 cannot enter the cavity 106. The liquid can be stored in a storage tank where the liquid can be maintained at a desired temperature or insulated to help avoid heat loss. The tank 210 can then be filled or at least partially filled with the liquid 212 to a sufficient level that the liquid 212 fills the cavity 106, as previously described. This Fig. 9 It is shown in Fig. 9 On the left side is shown an empty can 210 in which the closed mold assembly 100 is disposed, and Fig. 9 An example of a tank 210 filled with liquid 212 to a level that submerges the mold assembly 100 is shown on the right.

[0067] refer to Fig.10 and Fig.11 In some embodiments, liquid 212 is provided to cavity 106 without placing mold assembly 100 in a tank and without immersing or partially immersing mold assembly 100 in liquid 212. In such a configuration, as previously described, mold assembly 100 may include fewer openings or holes and may be configured such that when mold assembly 100 is closed, first mold 102 is sealed relative to second mold 104. In such a configuration, cavity 106 may be sealable or isolable from ambient air. Liquid 212 is provided to cavity 106, for example, from a fluid source 220. Fluid source 220 is fluidly connected to cavity 106. For example, fluid source 220 may be fluidly connected to mold assembly 100 via a conduit (e.g., a pipe, a hose, a tube, etc.). Mold assembly 100 may have one or more channels that are fluidly connected to the conduit and extend to a corresponding forming surface. Fluid source 220 may include a pump that may pressurize liquid 212 and force liquid 212 into cavity 106. As cavity 106 is filled in a manner known to those skilled in the art, the gas or air in cavity 106 may be vented. It is contemplated that the liquid level in cavity 106 may be monitored visually, for example, with a sight glass, or with a sensor, such as a level sensor, such as an optical sensor, a capacitance-based sensor, an ultrasonic sensor, a pressure-based sensor, a load cell, or the like.

[0068] Once the cavity 106 is filled with the liquid 212, the liquid 212 is held in the cavity 106 for a predetermined period of time. The predetermined period of time may vary based on many factors, such as the filament material, the temperature of the liquid, the temperature of the mold assembly 100, the temperature of the sheet of filament mesh structure 90 when inserted into the cavity 106, and the like. The predetermined period of time may be determined based on development testing. As a non-limiting example, the predetermined period of time may be greater than 1 minute, such as between 1 minute and 6 minutes; however, it is contemplated that in some configurations, the predetermined period of time may be less than one minute. When the liquid 212 is held in the cavity 106, the liquid 212 does not leave the mold assembly 100. For example, the cavity 106 may be filled with the liquid 212, and one or more valves may be closed to prevent the liquid 212 from leaving the cavity 106 and to prevent additional liquid 212 from entering the cavity 106. In this way, when the liquid 212 is held in the cavity 106, the liquid 212 does not circulate into or out of the cavity 106.

[0069] exist Figure 5 At frame 206, the filament mesh structure 90 is cooled in the cavity 106 of the mold assembly 100. When the filament mesh structure 90 is cooled, the mold assembly 100 remains closed. When the filament mesh structure 90 is in a compliant, softened state, removing the filament mesh structure 90 from the mold assembly 100 may cause an unintentional change or loss of the conforming shape provided by the forming surface. To solve this problem, the filament mesh structure 90 is cooled in the mold assembly 100 to set the shape of the filament mesh structure 90 to the forming surface. Cooling the filament mesh structure 90 in the mold assembly 100 includes cooling the filament mesh structure 90 to at least a second temperature threshold value less than the first temperature threshold value with a fluid. The second temperature threshold value is selected to be any temperature that effectively causes the filament mesh structure 90 to enter a non-compliant state. For example, for linear low density polyethylene, the second temperature threshold value can be lower than 85°C. The cooling fluid can be a gas, a liquid, or a combination of a gas and a liquid.

[0070] The filament mesh structure 90 can be cooled in various ways, see Figure 12-Figure 19 Some examples of these are discussed in Figure 12-Figure 15 In the embodiment of the present invention, cooling the filament web 90 includes removing the die assembly 100 from the tank 210. Figure 16-Figure 19 , cooling the filament web 90 does not include removing the die assembly 100 from the tank 210 .

[0071] refer to Fig.12 and Fig.13 In some embodiments, cooling the filament web 90 includes removing the die assembly 100 from the tank 210 and cooling the filament web 90 with gas. Fig.13214 . The mold assembly 100 can be removed from the tank 210 by positioning the cavity 106 or the entire mold assembly 100 above the top surface 214 of the liquid 212 (e.g., using a crane or a movable platform). When the mold assembly 100 is removed from the liquid 212, the liquid 212 is discharged from the cavity 106 via various holes or openings in the mold assembly 100. When the liquid 212 is discharged from the cavity 106, the liquid 212 is replaced by a gas from the surrounding environment. For example, the gas can be air. The gas entering the cavity 106 is provided at a temperature lower than the second predetermined temperature. As a result, when the mold assembly 100 is removed from the tank 210, the filament mesh structure 90 is cooled by the gas entering the cavity. Removing the mold assembly 100 from the tank 210 allows the tank 210 to be used to receive another filament mesh structure 90, which can help increase production.

[0072] refer to Fig.14 and Fig.15 In some embodiments, cooling the filament web 90 includes removing the mold assembly 100 from the tank 210 and cooling the filament web 90 with liquid in the second tank 230. Fig.15 2. The mold assembly 100 is removed from the tank 210 and placed in the second tank 230. The mold assembly 100 may be removed from the tank 210 and lowered into the second tank 230 or otherwise positioned in the second tank 230 using a crane, lift, hoist or other suitable material handling device. As previously described, when the mold assembly 100 is removed from the liquid 212 and replaced with a gas (e.g., air), the liquid 212 in the tank 210 is forced out of the cavity 106. As a result, some cooling with the gas may occur during the transport of the mold assembly 100 from the tank 210 to the second tank 230. As the mold assembly 100 is lowered into the liquid 232, the gas is replaced by the liquid 232 in the second tank 230. The liquid 232 in the second tank 230 is provided at a temperature below the second predetermined temperature. As a result, when the mold assembly 100 is placed in the second tank 230 , the filamentary web 90 is cooled in the mold assembly 100 with the liquid 232 entering the cavity 106 , thereby setting the shape of the filamentary web 90 to the forming surface of the mold assembly 100 .

[0073] refer to Fig.16 and Fig.17 In some embodiments, the filament mesh structure 90 is cooled with gas in the tank 210. The filament mesh structure 90 can be cooled in the tank 210 by draining the liquid 212 from the tank 210 so that gas from the surrounding environment, such as air, enters the cavity 106 and cools the filament mesh structure 90. This is similar to Fig.12 and Fig.13100, but rather than removing the mold assembly 100 from the liquid 212 in the tank 210, the liquid 212 is removed from the tank 210 and the mold assembly 100. The liquid 212 can be removed from the tank 210 by, for example, draining the tank 210 by opening a drain valve. The tank 210 is drained to at least below the level of the cavity 106, thereby allowing gas to enter the cavity 106 to replace the liquid 212. Draining the tank 210 can help avoid material handling operations associated with removing the mold assembly 100 from the tank 210, which can help reduce cycle time.

[0074] exist Fig.18 and Fig.19 In some embodiments, the filament mesh structure 90 is cooled with a liquid in the tank 210. This can be achieved in a variety of ways.

[0075] In some configurations, the liquid 212 in the tank 210 is cooled to a temperature below the second temperature threshold, thereby cooling the filament mesh structure 90 in the mold assembly 100 to set the shape of the filament mesh structure 90 to form the surface. For example, the liquid 212 can be circulated from the cavity 106 to a heat exchanger or other cooling device that cools the liquid 212. The liquid 212 can return to the cavity 106 at a lower temperature to facilitate cooling of the filament mesh structure 90. The liquid 212 can return to the cavity 106 below the second temperature threshold, or can be circulated through the heat exchanger or cooling device multiple times to sufficiently cool the liquid 212 to below the second temperature threshold.

[0076] In some configurations, the liquid 212 is drained from the cavity 106 and replaced by a liquid having a temperature below the second temperature threshold. For example, the heated liquid 212 can be drained from the tank 210, thereby draining from the cavity 106. The tank 210 can then be filled with a liquid 212' having a temperature below the second temperature threshold, thereby filling the cavity 106 with a cooler liquid 212'. Cooling with a liquid rather than a gas can result in faster cooling of the filament mesh structure 90.

[0077] In a configuration where the tank 210 is not used, for example Fig.10 and Fig.11 In connection with the illustrated configuration, cooling can be achieved by draining the liquid 212 from the cavity 106 after maintaining the liquid 212 in the cavity 106 for a predetermined period of time and replacing the liquid 212 with a gas. For example, the liquid 212 can be drained from the cavity 106 and replaced by a gas having a temperature below the second temperature threshold, which cools the filament mesh structure 90.

[0078] In some configurations where tank 210 is not employed, cooling may be achieved by draining liquid 212 from cavity 106 after maintaining liquid 212 in cavity 106 for a predetermined period of time, and then providing liquid having a temperature below a second temperature threshold into cavity 106 to cool filament mesh structure 90. The drained heated liquid may be stored to help maintain the heated liquid at an elevated temperature, which may reduce energy consumption compared to configurations in which liquid having a temperature below the second temperature threshold is mixed with the heated liquid to reduce the overall temperature of the liquid.

[0079] At block 208, the mold assembly 100 is opened and the cooled filamentary web structure 90 is removed from the cavity 106. The cooled filamentary web structure 90 may now be ready for installation in a seat assembly or may undergo further manufacturing steps.

[0080] Item 1. A method comprising: placing a mesh member in a cavity of a mold assembly, the mold assembly including a forming surface; adding a liquid having a temperature above a first temperature threshold into the cavity to soften the mesh member and conform the shape of the mesh member to the forming surface; and cooling the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

[0081] Clause 2. The method of clause 1, wherein liquid is added to the cavity while the mold assembly is disposed in a tank.

[0082] Clause 3. The method of Clause 2, wherein at least a portion of the mold assembly is disposed in the can when the mesh member is placed in the cavity of the mold assembly.

[0083] Clause 4. The method of Clause 2, further comprising placing the mold assembly in the can after placing the mesh member in the cavity.

[0084] Clause 5. The method of Clause 4, wherein the tank contains a liquid prior to placing the mold assembly in the tank.

[0085] Clause 6. The method of Clause 4 or Clause 5, wherein placing the mold assembly in the tank comprises submerging the mold assembly in the liquid.

[0086] Clause 7. The method of Clause 4, wherein adding liquid comprises at least partially filling the tank with liquid after placing the mold assembly in the tank.

[0087] Clause 8. The method of any preceding clause, wherein cooling the mesh member comprises removing the mold assembly from the tank.

[0088] Clause 9. The method of Clause 8, wherein cooling the mesh member comprises cooling the mesh member with a gas.

[0089] Clause 10. The method of Clause 9, wherein cooling the mesh member comprises cooling the mesh member with air entering the cavity when the mold assembly is removed from the can.

[0090] Clause 11. A method according to any one of clauses 8 to 10, wherein cooling the mesh member comprises placing the mold assembly in a second tank containing a liquid, the liquid comprising a temperature below a second temperature threshold, wherein the liquid in the second tank enters the cavity and cools the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

[0091] Clause 12. The method of any one of Clauses 2 to 7, wherein cooling the mesh member comprises cooling the mesh member in the tank.

[0092] Clause 13. The method of Clause 12, wherein cooling the mesh member comprises draining liquid from the tank so that air enters the cavity and cools the mesh member.

[0093] Clause 14. The method of clause 12, wherein cooling the mesh member comprises cooling the liquid in the tank and the cavity to below a second temperature threshold, thereby cooling the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

[0094] Clause 15. A method according to clause 12 or clause 13, wherein cooling the mesh member includes draining liquid from the cavity and adding liquid below a second temperature threshold to the tank so that the liquid at least partially immerses the mold assembly and enters the cavity, thereby setting the shape of the mesh member to the forming surface.

[0095] Clause 16. The method of Clause 1, wherein adding the liquid comprises filling the cavity with the liquid and maintaining the liquid in the cavity for a predetermined period of time.

[0096] Clause 17. The method of Clause 16, wherein liquid does not exit the mold assembly while liquid is retained in the cavity.

[0097] Clause 18. A method according to clause 16 or clause 17, wherein cooling the mesh member includes replacing the liquid in the cavity with a liquid having a temperature below a second temperature threshold, and the liquid having a temperature below the second temperature threshold cools the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

[0098] Clause 19. A method according to clause 16 or clause 17, wherein cooling the mesh member includes draining the liquid from the cavity after maintaining the liquid in the cavity for the predetermined period of time, and then providing liquid having a temperature below a second temperature threshold into the cavity, wherein the liquid having a temperature below the second temperature threshold cools the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

[0099] Clause 20. Any combination of any of the preceding clauses 1-20.

[0100] Clause 21. A cushion for a seat assembly, the cushion comprising the web member formed by the method of any preceding clause.

[0101] Although exemplary embodiments are described above, this does not mean that these embodiments describe all possible forms of the present invention. Rather, the words used in this specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present invention. In addition, the features of various implementation embodiments may be combined to form additional embodiments of the present invention.

Claims

1. A method comprising: placing a mesh member in a cavity of a mold assembly, the mold assembly comprising a forming surface; adding a liquid having a temperature above a first temperature threshold into the cavity, thereby softening the mesh member and conforming the shape of the mesh member to the forming surface; as well as The mesh member in the mold assembly is cooled to set the shape of the mesh member to the forming surface.

2. The method according to claim 1, wherein: When the mold assembly is positioned in the tank, liquid is added to the cavity.

3. The method according to claim 2, wherein: When the mesh member is placed in the cavity of the mold assembly, at least a portion of the mold assembly is disposed in the can.

4. The method of claim 2, further comprising placing the mold assembly in the can after placing the mesh member in the cavity.

5. The method according to claim 4, wherein: Prior to placing the mold assembly in the tank, the tank contains a liquid.

6. The method according to claim 5, wherein: Placing the mold assembly in the tank includes submerging the mold assembly in the liquid.

7. The method according to claim 4, wherein: Adding the liquid includes at least partially filling the tank with the liquid after placing the mold assembly in the tank.

8. The method according to claim 2, wherein: Cooling the mesh member includes removing the mold assembly from the tank.

9. The method according to claim 8, wherein: Cooling the mesh member includes cooling the mesh member with a gas.

10. The method according to claim 9, wherein: Cooling the mesh member includes cooling the mesh member with air entering the cavity when the mold assembly is removed from the can.

11. The method according to claim 8, wherein: Cooling the mesh member includes placing the mold assembly in a second tank containing a liquid, the liquid comprising a temperature below a second temperature threshold, wherein the liquid in the second tank enters the cavity and cools the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

12. The method according to claim 2, wherein: Cooling the mesh member includes cooling the mesh member in the tank.

13. The method according to claim 12, wherein: Cooling the mesh member includes draining liquid from the tank so that air enters the cavity and cools the mesh member.

14. The method according to claim 12, wherein: Cooling the mesh member includes cooling the liquid in the tank and the cavity to below a second temperature threshold, thereby cooling the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

15. The method according to claim 12, wherein: Cooling the mesh member includes draining liquid from the cavity and adding liquid below a second temperature threshold to the tank such that the liquid at least partially immerses the mold assembly and enters the cavity to shape the mesh member to the forming surface.

16. The method according to claim 1, wherein: Adding the liquid includes filling the cavity with the liquid and maintaining the liquid in the cavity for a predetermined period of time.

17. The method according to claim 16, wherein: While liquid is retained in the cavity, the liquid does not exit the mold assembly.

18. The method according to claim 16, wherein: Cooling the mesh member includes replacing liquid in the cavity with liquid having a temperature below a second temperature threshold, the liquid having a temperature below the second temperature threshold cooling the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

19. The method according to claim 16, wherein: Cooling the mesh member includes draining the liquid from the cavity after maintaining the liquid in the cavity for the predetermined period of time, and then providing liquid having a temperature below a second temperature threshold into the cavity, wherein the liquid having a temperature below the second temperature threshold cools the mesh member in the mold assembly to set the shape of the mesh member to the forming surface.

20. A cushion for a seat assembly, the cushion comprising the mesh member formed by the method of claim 1.

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