Carrier on fabric

Abstract

A seat assembly includes a fabric member having a seat surface and a carrier attached to the fabric member. The carrier includes a variable thickness along an outer periphery of the carrier. The fabric component includes two or more tension zones.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 525,759, filed on July 10, 2023, entitled “FRAME OVER FABRIC WITH FLEXRETURN FLANGE,” and U.S. Provisional Patent Application No. 63 / 533,497, filed on August 18, 2023, entitled “FRAME OVER FABRIC,” which are incorporated herein by reference in their entirety. Background Art Technical Field

[0003] Examples of the present disclosure relate generally to fabric suspended seat structures and, more particularly, to fabric suspended seat structures having a molded carrier.

[0004] BACKGROUND OF THE DISCLOSURE

[0005] Seating assemblies, such as office furniture, often use fabric suspended structures. Typically, fabric suspended seating structures include a support carrier disposed along the periphery of the fabric. The fabric extends across the support carrier to provide a surface upon which a user may sit. The fabric is typically secured to the support carrier, which is then attached to a support frame that couples the suspended structure to the furniture. In order to provide proper suspension, the fabric is stretched and then the carrier is overmolded to the fabric. Current methods of stretching the fabric prior to overmolding require clamps and various motors to tension the taught fabric; however, the cost of purchasing, installing, and maintaining such clamps and motors can be high. Summary of the invention

[0006] In some aspects, a seat assembly includes a fabric component defining a seat surface and a carrier molded to the fabric component. The carrier includes a curved parting line around the periphery of the carrier. The fabric component includes a plurality of tension zones. Two or more tension zones can be converted into a plurality of compressible soft zones and a plurality of firm comfort zones.

[0007] In some embodiments, the carrier includes an upper section and a lower section with a parting line disposed therebetween. In some embodiments, the distance between the upper surface of the upper section opposite the parting line and the parting line is variable along the parting line. In some embodiments, the thickness of the upper section or the lower section is variable along the periphery of the corresponding section. In some embodiments, the fabric component at least partially comprises a resin material. In some embodiments, the carrier at least partially comprises a material having a melting temperature higher than the melting temperature of the material of the fabric component. In some embodiments, two of the tension zones are configured to receive and support different weights. In some embodiments, the fabric is pre-tensioned before the carrier is molded to the fabric. In some embodiments, the curved parting line defines a plurality of inflection points.

[0008] In some aspects, a seat assembly includes a fabric component having a seat surface and a carrier molded to the fabric component. The carrier includes a curved parting line along a periphery of the carrier, and the curved parting line defines a plurality of inflection points. In some embodiments, the fabric component includes a plurality of tension zones created by the curved parting line. In some embodiments, two of the tension zones are configured to receive and support different weights. In some embodiments, the carrier includes an upper section and a lower section with the parting line disposed therebetween. In some embodiments, the thickness of the upper section or the lower section is variable along the periphery of the respective section. In some embodiments, the fabric component is a knitted fabric.

[0009] In some aspects, a manufacturing method includes tensioning a fabric component between a first mold base and a second mold base, and molding a carrier onto the fabric component. The carrier includes a curved parting line around the periphery of the carrier, and the fabric is tensioned to include a plurality of tension zones. In some embodiments, the carrier includes an upper section and a lower section with the parting line disposed therebetween. In some embodiments, the height of the first mold base or the second mold base is variable. In some embodiments, the carrier is formed within a cavity defined between the first mold base or the second mold base. In some embodiments, the curved parting line is formed by an undulating cavity between the first mold base or the second mold base. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a perspective view of one example of components of a seat assembly;

[0011] Figure 2 yes Figure 1 A perspective view of components of a seat assembly;

[0012] Figure 3 It is used to manufacture Figure 1 A three-dimensional view of a mold of a seat assembly;

[0013] Figure 4 It is used to manufacture Figure 1a three-dimensional view of a mold of a seat assembly; and

[0014] Figure 5 is a simplified example diagram of a molding process used to manufacture a seat assembly. DETAILED DESCRIPTION

[0015] Examples of the present disclosure provide a seat assembly including a fabric and a carrier. A flexible or rigid carrier is configured to be molded directly to a peripheral section of a fabric component. In some examples, the carrier can include a variable height or parting line position around the periphery of the carrier. In this way, the seat assembly can variably distribute stress as needed during loading of the fabric component to manage comfort goals and various body shapes and sizes.

[0016] Examples of the present disclosure further provide a method of overmolding a variable thickness carrier onto a fabric without requiring external clamps, cores, lifters, or motors to pre-stretch the fabric. Although the method described below does not require clamps, cores, lifters, or motors to stretch the fabric prior to the overmolding process, it is contemplated that external clamping assemblies may still be utilized.

[0017] refer to Figure 1 and Figure 2 , in one aspect, a seat assembly 100 is shown that includes a fabric component 104 or seat member. The fabric component 104 has a top surface 108 opposite a bottom surface and extends across a carrier 116 or carrier member such that the fabric component 104 is stretched or tensioned to provide the top surface 108 or seat surface in a suspended state and capable of supporting a user in a seated position.

[0018] like Figure 1 and Figure 2As shown, the fabric component 104 includes a plurality of fibers that are woven or arranged together, wherein all or some of the fibers are formed by a flexible material or resin. For example, the fabric component 104 may include a knitted component, a woven textile, a nonwoven textile, leather, synthetic leather, mesh, suede and / or a combination of one or more of the foregoing materials. The fabric component 104 may be formed by warp knitting, weft knitting, flat knitting, circular knitting and / or other suitable knitting operations. For example, the fabric component 104 may have a plain knit structure, a mesh knit structure, and / or a rib knit structure. For example, woven textiles include but are not limited to textiles formed by any one of a variety of weaving forms (such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double-sided weave, and / or double-layer cloth weave). For example, nonwoven textiles include textiles made, for example, by air-laid and / or spun-laid methods. The fabric component 104 may include a variety of materials, which may have different properties or visual features. For example, some or all of the fibers of fabric component 104 may be formed of fiberglass or a thermoplastic material or resin or a combination thereof. The plurality of fibers may be bonded or secured together and oriented longitudinally relative to each other and along the front-to-back length of carrier 116 or the left-to-right length of carrier 116. The melting temperature of fabric component 104 depends at least in part on the selection or combination of materials or resins of the plurality of fibers, and the fabric component may be configured to have an average melting temperature that is lower than the average melting temperature of the material of carrier 116.

[0019] Continue to refer Figure 1 and Figure 2, the carrier 116 includes an upper carrier section 120 and a lower carrier section 124. As further described below, the upper carrier section 120 and the lower carrier section 124 can be compressed relative to each other to tension the fabric 104. In some embodiments, the upper carrier section 120 includes a variable height or topographic edge 128. The topographic edge 128 faces the lower carrier section 124. The topographic edge 128 extends from a middle section 132 of the upper carrier section 120, which varies in thickness and shape along the carrier 116. Therefore, when viewed from the side, the topographic edge 128 defines a curve or undulation along the topographic edge. It should be understood that the lower carrier section 124 can similarly define a variable thickness around the periphery of the lower carrier section 124. However, in some embodiments, the lower carrier section 124 defines a uniform thickness. As further described below, in some embodiments, the upper carrier segment 120 is joined to the lower carrier segment 124 to form the carrier 116. The fabric 104 is tensioned between the upper carrier segment 120 and the lower carrier segment 124. The fabric 104 can form a parting line between the upper carrier segment 120 and the lower carrier segment 124 (e.g., at the topographic edge 128). Due to the variable thickness of the upper carrier segment and / or the lower carrier segment 124, the parting line therebetween is curved, thereby defining a variable distance between the parting line and the upper surface of the upper carrier segment 120 (e.g., the surface opposite the topographic edge 128). In some embodiments, the curvature of the parting line defines a plurality of inflection points. In some embodiments, the parting line is symmetrical about one or more axes (e.g., a central axis) of the carrier 116. In other embodiments, the parting line is asymmetrical.

[0020] The carrier 116 may be integrally formed from a material or resin, or a combination thereof, which may include a resilient polymer, such as any thermoplastic. For example, the thermoplastic may include nylon, glass-filled nylon, polypropylene, acetyl, or polycarbonate; any thermoset material, including polyester and epoxy; or any resin-based composite material, including carbon fiber or glass fiber, thereby allowing the carrier 116 to conform to and move in response to the force applied by the user. The carrier 116 can be formed from a variety of polymeric materials, including, for example, polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), crystalline PET, amorphous PET, polyethylene terephthalate, polystyrene (PS), polyamide (PA), polyvinyl chloride (PVC), polycarbonate (PC), poly(styrene:acrylonitrile) (SAN), polymethyl methacrylate (PMMA), polypropylene (PP), polyethylene naphthalate (PEN), polyethylene furanoate (PEF), PET homopolymer, PEN copolymer, PET / PEN resin blend, PEN homopolymer, overmolded thermoplastic elastomer (TPE), fluoropolymer, polysulfone, polyimide, cellulose acetate, silicone, PBT and / or combinations thereof.

[0021] refer to Figure 1 and Figure 2 , the carrier 116 includes a front end 144, a rear end 148, a left end 152, and a right end 156. A longitudinal axis 160 extends from the front end 144 to the rear end 148 and further defines a vertical plane that bisects the seat assembly 100 and defines a horizontal plane that is coplanar with the top surface 108 of the fabric component 104. A transverse axis 164 extends coplanar with the longitudinal axis 160 and perpendicular to the longitudinal axis from the left end 152 to the right end 156 of the carrier 116 and further defines a vertical plane that bisects the seat assembly 100. Thus, the intersection between the longitudinal axis 160 and the transverse axis 164 defines a center point C of the seat assembly 100.

[0022] like Figure 1 and Figure 2 As shown, the carrier 116 is symmetrical about the longitudinal axis 160, such that the shape and size of the carrier 116 at the right end 156 is a mirror image of the shape and size of the carrier 116 at the left end 152. In the illustrated example, the carrier 116 is also symmetrical about the transverse axis 164, such that the shape and size of the carrier 116 at the front end 144 is a mirror image of the shape and size of the carrier 116 at the rear end 148. However, in some embodiments, the shape and size of the carrier 116 at the front end 144 is different than the shape and size of the carrier 116 at the rear end 148, such that the carrier 116 is asymmetrical about the transverse axis 164.

[0023] like Figure 1 and Figure 2 As depicted, as the upper carrier section 120 extends around the fabric member 104, its thickness and shape change. The fabric member 104 is tensioned between the front end 144 and the rear end 148 of the carrier 116, and further between the left end 152 and the right end 156. Specifically, the non-uniformity of the topographic edge 128 and the variable thickness of the upper carrier section 120 and / or the lower carrier section 124 can uniquely tension the fabric member 104. Therefore, the fabric member 104 is tensioned in multiple opposite directions and is resilient, thereby defining equal and opposite force vectors between the fabric member 104 and the carrier 116. Therefore, the fabric member is molded to the carrier 116 to provide a suspension force that is configured to support the user when the user sits on the top surface 108 of the fabric member 104. The fabric member 104 can be substantially horizontal and planar in an unloaded state.

[0024] Due to the weight of the user when sitting on the top surface 108 of the fabric component 104, the fabric component 104 deflects downwardly below the horizontal plane formed by the longitudinal axis 160 and below the upper surface (e.g., opposite the topographic edge 128) of the upper carrier section 120. In this way, the fabric component 104 provides a suspended or hammock-like support to the user sitting on the top surface 108. As further described below, the variation in the thickness of the upper carrier section 120 and / or the lower carrier section 124 can help to produce zoned tensioning. Specifically, the parting line disposed between the upper carrier section 120 and the lower carrier section 124 defines a variable height (e.g., the distance between the parting line and the uppermost surface or the lowermost surface of the seat assembly 100), which enables the generation of zoned tensioning. Zoned tensioning refers to the fact that zones or regions of the fabric component 104 are tensioned or stretched differently to offset the variable input forces from the mannequin or human occupant. For example, a region intended to accommodate a human buttock can be tensioned differently from a region intended to accommodate a human thigh.

[0025] Reference now Figure 3 and Figure 4 , a mold 200 for overmolding the carrier 116 onto the fabric component 104 is shown. The mold 200 includes a first mold base 204 and an opposing second mold base 208. The first mold base 204 includes a first mold core 212, and the second mold base 208 includes a second mold core 216. The first mold core 212 and the second mold core 216 extend from the first mold base 204 and the second mold base 208, and are configured to clamp and tension the fabric component 104 before and during molding the seat assembly 100. The outer peripheral shape of the first mold core 212 and the second mold core 216 may be similar to the shape of the carrier 116. In other embodiments, the outer peripheral shape of the first mold core 212 and the second mold core 216 may not be similar to the shape of the carrier 116.

[0026] like Figure 3 and Figure 4 As depicted, the first mold core 212 extends from the first mold base 204 at a first height 220. The first height 220 of the first mold core 212 can be variable around the periphery of the first mold core 212, thereby forming a continuous curve with one or more inflection points. Therefore, the first mold base 204 defines a variable height. Similarly, the second mold core 216 extends from the second mold base 208 at a second height 224. The second height 224 of the second mold core 216 can also be variable around the periphery of the second mold core 216, thereby forming a continuous curve with one or more inflection points. Therefore, the second mold base 208 defines a variable height. In some embodiments, the shape, height, and size of the second mold core 216 can be the negative value of the shape, height, and size of the first mold core 212. Therefore, the first mold core 212 and the second mold core 216 can be engaged together to form a seal.

[0027] One of the first mold core 212 or the second mold core 216 can be moved within the first mold holder 204 or the second mold holder 208, respectively. The first mold holder 204 and the second mold holder 208 can be closed by moving toward each other. In some embodiments, the first mold holder 204 moves toward the second mold holder 208, the second mold holder 208 moves toward the first mold holder 204, or the first mold holder 204 and the second mold holder 208 move toward each other. The first mold core 212 or the second mold core 216 can be moved within the mold 200 to allow the first mold core 212 or the second mold core 216 to fold or retract within the first mold holder 204 or the second mold holder 208. When the first mold holder 204 and the second mold holder 208 are closed, the first mold core 212 and the second mold core 216 contact each other, causing one of the first mold core 212 or the second mold core 216 to fold or retract within the first mold holder 204 or the second mold holder 208. The first mold core 212 or the second mold core 216 can be connected to one or more springs, hydraulic pistons, electric motors, or electromagnets, which can firstly resist the movement of the first mold core 212 or the second mold core 216, and secondly, once the mold 200 is opened and the final product is released, it can return the first mold core 212 or the second mold core 216 to the original position.

[0028] refer to Figure 3 , the mold longitudinal axis 228 extends from the mold front end 232 to the mold rear end 236 and further defines a vertical plane bisecting the mold 200. The mold transverse axis 240 is coplanar with the mold longitudinal axis 228 and extends perpendicular to the mold longitudinal axis from the mold left end 244 to the mold right end 248. Thus, the intersection between the mold longitudinal axis 228 and the transverse axis 240 defines the center point CM of the mold.

[0029] refer to Figure 4, and similar to the carrier 116, the first mold core 212 and the second mold core 216 are symmetrical about the longitudinal axis 228, such that the height, shape, and size of the first mold core 212 and the second mold core 216 at the right end 248 of the mold are mirror images of the height, shape, and size of the first mold core 212 and the second mold core 216 at the left end 244 of the mold. However, in some embodiments, the first mold core 212 and the second mold core 216 are asymmetrical about the longitudinal axis 228, such that the height, shape, and size of the first mold core 212 and the second mold core 216 at the right end 248 of the mold are not mirror images of the height, shape, and size of the first mold core 212 and the second mold core 216 at the left end 244 of the mold. In the illustrated example, the first core 212 and the second core 216 are also symmetrical about the mold transverse axis 240, such that the height, shape, and size of the first core 212 and the second core 216 at the mold front end 232 are mirror images of the height, shape, and size of the first core 212 and the second core 216 at the mold rear end 236. However, in some embodiments, the height, shape, and size of the first core 212 and the second core 216 at the mold front end 232 are different from the height, shape, and size of the first core 212 and the second core 216 at the mold rear end 236, such that the first core 212 and the second core 216 are asymmetrical about the mold transverse axis 240.

[0030] Once the mold 200 is closed, the fabric component 104 is clamped between the first mold core 212 and the second mold core 216. The closed mold 200 forms a carrier cavity 252 between the first mold core 212 and the second mold core 216, which is configured to form a carrier 116 with a curved parting line. Specifically, similar to the height of the first mold base 204 and the second mold base 208 and the curved parting line, the carrier cavity 252 undulates and defines a plurality of inflection points. Therefore, when the fabric component 104 is clamped between the first mold core 212 and the second mold core 216, the fabric component 104 is stretched and pre-tensioned across the carrier cavity 252. The carrier material is then injected into the carrier cavity 252 and can flow around and through the fabric component 104. Once the carrier material hardens into the carrier 116, the carrier 116 is chemically and mechanically bonded to the fabric component 104.

[0031] The various symmetries of the first mold core 212 and the second mold core 216 are configured to aid in the molding of the carrier 116, as described above, for example, with variable thickness and shape as the carrier 116 extends around the fabric member 104. More specifically, when the carrier material is injected into the mold 200, the thickness of the upper carrier segment 120 and the lower carrier segment 124 can vary in a manner similar to the variation of the first height 220 and the second height 224 of the first mold core 212 and the second mold core 216. The different heights and shapes of the first mold core 212 and the second mold core 216 are further configured to provide zoned tensioning to the fabric member 104 prior to injection of the carrier material. Specifically, the portions of the first mold core 212 and the second mold core 216 with greater heights produce higher tension zones, while the portions of the first mold core 212 and the second mold core 216 with less heights produce lower tension zones.

[0032] The seat assembly 100 is manufactured to form multiple tension zones (e.g., two, three, four, five, six, seven, eight, nine, ten or more tension zones) in the fabric 104. In some embodiments, each of the tension zones is configured to receive and support a different weight or force. In some embodiments, two or more of the tension zones are configured to receive and support similar weights and forces.

[0033] refer to Figure 5, discloses an example of a molding process 300 that may be used to attach a fabric blank 304 similar to fabric component 104 to a carrier support similar to carrier 116 . It is contemplated that the seat assembly 100 can be manufactured in a variety of ways or steps and by using a variety of machines or materials, such as those described in the following patents, U.S. Patent No. 7,618,572, entitled “Method and Apparatus for Manufacturing Load Bearing Fabric Support Structures,” U.S. Patent No. 7,677,873, entitled “Apparatus and Method for Molding onto a Stretched Blank,” U.S. Patent No. 8,066,501, entitled “Apparatus and Method for Molding onto a Stretched Blank,” and U.S. Patent No. 9,156,211, entitled “Apparatus and Method for Manufacturing a Load Bearing Fabric Surface,” all of which are assigned to Illinois Tool Works Inc. and are incorporated herein by reference in their entirety. It is further contemplated that various alternative manufacturing methods may be used to manufacture the seat assembly 100 , such as various types of additive manufacturing or subtractive manufacturing.

[0034] like Figure 5 As shown, the molding process 300 is depicted in a simplified manner with five stages moving from left to right on the page, which will be referred to herein as the first stage, the second stage, the third stage, the fourth stage, and the fifth stage. Starting from the first stage of the molding process 300, the fabric blank 304 is Figure 3 and Figure 4 Optionally, the second stage involves attaching a heat shield 308 to the side of the fabric blank 304 that is exposed to the second mold base 208. The heat shield 308 can be reused in multiple molding processes 300, so the heat shield 308 is a polyester film made of PET or biaxially oriented PET (BoPET) (trade name ) or similar substances having similar properties.

[0035] The third stage involves moving the first mold holder 204 or the second mold holder 208 toward each other to form a molded compression piece 312 or a closed mold. When the first mold holder 204 and the second mold holder 208 move together, the first mold core 212 and the second mold core 216 engage together and clamp the fabric blank 304, thereby locking the fabric blank 304 in place.

[0036] As the first mold holder 204 and the second mold holder 208 continue to move toward each other, one of the first mold core 212 or the second mold core 216 begins to retract within the first mold holder 204 or the second mold holder 208. As the first mold core 212 or the second mold core 216 continues to retract within the first mold holder 204 or the second mold holder 208, respectively, the fabric blank 304 is pulled into an increasingly tensioned state. As described above, the variable heights of the first mold core 212 and the second mold core 216 help to create zoned tension on the fabric blank 304.

[0037] During the third stage, the carrier 16 is formed by injecting a liquid material (e.g., a thermoplastic material) through the carrier cavity 252, which is designed and arranged to be filled with the liquid material. As described above, the thermoplastic material can flow through the carrier cavity 252 and flow through and around the fabric blank 304 stretched across the carrier cavity 252. Further, cooling lines can be installed throughout the molding compression member 312, which can be in the first mold base 204, in the second base mold 208, or in both. The cooling lines are designed to remove heat from specific areas or portions of the mold at specific times within the molding process 300. For example, the cooling lines can be designed to produce a one-piece carrier 116 with thinner and more flexible sections or thicker and less flexible sections. In addition, the cooling lines can be designed to prevent some portions of the fabric blank 304 from annealing.

[0038] Next, the fourth stage of the molding process 300 includes opening the molding compression member 312 and removing or ejecting the seat assembly 316 from the first mold base 204 or the second mold base 208, the seat assembly 316 including the carrier 116 molded to the fabric blank 304. As described above, the first mold core 212 or the second mold core 216 can be returned to the original position, which can facilitate the removal of the final product from the mold 200. In this fourth stage, excess fabric 320 is present in the seat assembly 316, and the optional heat shield 308 remains fixed to the fabric blank 304.

[0039] Finally, the fifth stage of the molding process 300 involves removing excess fabric 320 from the seat assembly 316 and optionally separating the heat shield 308 from the fabric blank 304. The heat shield 308 can then be used in another molding process 300, or the heat shield can be shipped as part of the seat assembly 316 and removed or discarded by the end user. For example, the heat shield 308 can have aesthetic features that make it suitable for shipping with the seat assembly 316 to the end user, such as carrying a company logo, color, wording, shape, or other non-functional purpose.

[0040] It is contemplated that the seat assemblies described herein may be used in a variety of different applications, such as in furniture for residential, commercial, recreational, transportation, or office applications. Alternatively, the seat assemblies described may have broader applications, such as in industrial machinery, outdoor sporting equipment, or recreational equipment. For example, the seat assemblies described herein may be applied to office furniture, motor vehicles, aircraft, lawn mowers, boats, stadium seating, trampolines, or theaters.

[0041] Although various spatial and directional terms such as top, bottom, lower, middle, lateral, horizontal, vertical, front, rear, etc. may be used to describe embodiments of the present disclosure, it should be understood that such terms are used only with respect to the orientations shown in the accompanying drawings. These orientations may be reversed, rotated, or otherwise changed so that an upper portion is a lower portion, vice versa, horizontal becomes vertical, etc.

[0042] Variations and modifications of the foregoing are within the scope of the present disclosure. It should be understood that the examples disclosed and defined herein extend to all alternative combinations of two or more individual features mentioned in the text and / or the accompanying drawings or apparent from the text and / or the accompanying drawings. All of these different combinations constitute a variety of different alternative aspects of the present disclosure. To the extent permitted by the prior art, the claims should be interpreted as including alternative examples.

Claims

1. A seat assembly, comprising: a fabric component defining a seat surface; as well as a carrier, the carrier being molded to the fabric member, wherein the carrier comprises a curved parting line around a periphery of the carrier, and Wherein, the fabric comprises a plurality of tension zones.

2. The seat assembly of claim 1, wherein: The carrier comprises an upper section and a lower section, and Wherein, the parting line is arranged therebetween.

3. The seat assembly of claim 2, wherein: A distance between an upper surface of the upper section opposite to the parting line and the parting line is variable along the parting line.

4. The seat assembly of claim 2, wherein: The thickness of the upper section is variable along a circumference of the upper section.

5. The seat assembly of claim 2, wherein: The thickness of the lower section is variable along a circumference of the lower section.

6. The seat assembly of claim 1, wherein: The fabric member at least partially contains a resin material.

7. The seat assembly of claim 1, wherein: The carrier at least partially comprises a material having a melting temperature higher than the melting temperature of the material of the textile element.

8. The seat assembly of claim 1, wherein: Two of the tension zones are configured to receive and support different weights.

9. The seat assembly of claim 1, wherein: The fabric is pre-tensioned before the carrier is molded to the fabric.

10. The seat assembly of claim 1, wherein: The curved parting line defines a plurality of inflection points.

11. A seat assembly comprising: a fabric component having a seat surface; as well as a carrier, the carrier being molded to the fabric member, wherein the carrier comprises a curved parting line along a periphery of the carrier, and Wherein, the curved parting line defines a plurality of inflection points.

12. The seat assembly of claim 11, wherein: The fabric component includes a plurality of tension zones created by the curved parting line.

13. The seat assembly of claim 11, wherein: The carrier comprises an upper section and a lower section, and Wherein, the parting line is arranged therebetween.

14. The seat assembly of claim 13, wherein: The thickness of the upper section or the lower section is variable along the circumference of the upper section.

15. The seat assembly of claim 11, wherein: The textile element is a knitted fabric.

16. A method of manufacturing a seat assembly, the method comprising: tensioning the fabric member between the first die holder and the second die holder; as well as molding a carrier onto the fabric member; wherein the carrier comprises a curved parting line around a periphery of the carrier, and Therein, the fabric is tensioned to include a plurality of tension zones.

17. The method of claim 16, wherein: The carrier comprises an upper section and a lower section, and Wherein, the parting line is arranged therebetween.

18. The method of claim 17, wherein: The height of the first mold base or the second mold base is variable.

19. The method of claim 18, wherein: The carrier is formed in a cavity defined between the first mold base or the second mold base.

20. The method of claim 16, wherein: The curved parting line is formed by an undulating cavity between the first mold base or the second mold base.

Images