Retainer for seat assembly and method of assembly

Abstract

A retainer is described that includes an elongate member attached to a trim cover and a plurality of anchors extending from the elongate member. Each of the anchors has a body having a first end attached to the elongate member and a second end opposite the first end, the second end terminating in a pointed end. Each of the anchors has a plurality of barbs, each barb extending from the body in a direction away from the tip. For each anchor of the plurality of anchors, when the anchor is inserted into the pad, the material of the pad is clamped between the body and each of the barbs. A method of assembling a seat assembly is also described that includes providing a retainer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 366,676 filed on June 20, 2022 and Danish Patent Application No. PA202370028 filed on January 19, 2023, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0002] The present disclosure relates to a retainer, a seat assembly having the retainer, and an assembly method. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 is a perspective view of a non-limiting exemplary embodiment of a seat assembly; Figure 2A-2C is a perspective view of a non-limiting exemplary embodiment of a retainer according to the present disclosure; Figure 3 is a side view of a non-limiting exemplary embodiment of a retainer according to the present disclosure; Figure 4 is a side view of a non-limiting exemplary embodiment of a retainer according to the present invention inserted into a cushioning material; and Figure 5 is an exemplary flow chart illustrating a non-limiting exemplary embodiment of a method according to the present disclosure. 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 will be apparent to one of ordinary skill in the art that the various embodiments described may be practiced without including these specific details. In other instances, well-known methods, processes, parts, features, and elements are not described in detail to avoid unnecessarily obscuring the various aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily to scale; some features may be enlarged or minimized to show details of specific 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” and / or “at least one” includes functions performed by one element, functions performed by more than one element in a distributed manner, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[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 element. 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 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" as used herein refers to and covers any and all possible combinations of one or more of the associated listed items. It should also be understood that when used in this specification, the terms "includes", "including", "comprises" and / or "comprising" specify the presence of the features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or combinations thereof.

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

[0010] refer to Figure 1, a perspective view of a non-limiting exemplary embodiment of a seat assembly 10 is shown. The seat assembly 10 can be configured for use in a vehicle (such as, a motor vehicle like a car or truck). The seat assembly 10 can include a seat back 12 and a seat bottom 14. The seat back 12 can be configured to support the back of a seat occupant. The seat bottom 14 can be configured to support the seat occupant. In vehicle applications, the seat bottom 14 can be mounted to a support surface, such as a vehicle floor.

[0011] The seat back 12 may be pivotable relative to the seat bottom 14 about an axis 16. For example, one or more recliner mechanisms, pivot pins, etc. may pivotally connect the seat back 12 to the seat bottom 14. Alternatively, the seat back 12 or a portion thereof may not be pivotally connected to the seat bottom 14. For example, the seat back 12 may be pivotally mounted to the vehicle body structure, such as may be the case in some bench seat configurations.

[0012] The seat back 12 may include a headrest 20 that may be configured to support the head of a seat occupant. The headrest 20 may be disposed at the top of the seat back 12. The headrest 20 may be integral with the seat back 12, or may be a separate component that is adjustably positioned relative to the top of the seat back 12.

[0013] The seat back 12 and the seat bottom 14 may each have at least one seat cushion 30. The seat back 12 and the seat bottom 14 may also each have side bolsters 32 and a central seating portion 34 of the cushion 30. A seat component 36 may be secured to the cushion 30 using one or more retainers, as will be discussed in more detail below.

[0014] The seat component 36 can be disposed above the cushion 30 or on the cushion 30. The seat component 36 can have any suitable configuration and be of any suitable type. For example, the seat component 36 can be a decorative cover, a decorative cover material, or a decorative cover assembly that provides at least a portion of the visible outer surface of the seat assembly 10. The decorative cover 36 can include a plurality of decorative sheets that can be assembled in any suitable manner (such as by stitching). The decorative sheet can be made of any suitable one or more materials (such as fabric, leather, vinyl, or a combination thereof). The seat component 36 can also or alternatively be a component that is hidden by the decorative cover or disposed under the decorative cover and disposed on the cushion 30, such as a temperature regulating device (such as a heating pad or a heating mat), an inflatable device for enhancing the comfort of the seat occupant (such as lumbar support) or providing a massage function, a breathable material that helps the airflow of the ventilated seat, etc.

[0015] The cushion 30 may be at least partially concealed by the seat component 36 and may be supported directly or indirectly by a support structure of the seat assembly 10 (such as a frame, panel, support wire, etc.). The cushion 30 includes a three-dimensional mesh structure formed by randomly looped and bonded wires 60. Figure 4 Only a few examples of filaments are shown in the figure, and for simplicity, the filaments are illustrated by randomly drawn lines. For example, the filaments 60 can be extruded filaments made of a polymer material, such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin, polypropylene, polystyrene, or a combination thereof. As an example, the filaments 60 can be made of linear low-density polyethylene (LLDPE). The extruded filaments 60 can be randomly looped, curled, or tangled, and can be combined together where one filament 60 contacts another filament 60, thereby producing a lightweight, breathable cushion with openings or gaps between the filaments 60. A method of making an extruded filament mesh cushion is disclosed in U.S. Patent Application No. 17 / 555,875, entitled "System and Method of Making a Mesh Cushion," filed on December 20, 2021, a copy of which is attached hereto as Appendix A. Therefore, the cushion 30 may not be made of a foam such as polyurethane foam, and may partially or completely replace a conventional polyurethane foam cushion. Alternatively, the cushion may be a conventional foam cushion, such as a polyurethane foam cushion.

[0016] Figure 2A-2C is a perspective view of a non-limiting exemplary embodiment of a retainer 40 according to the present disclosure. As seen in the figure, and with continued reference to Figure 1 , the retainer 40 in each embodiment includes an elongated member 42 and a plurality of anchors 44. In this regard, the elongated member 42 includes a planar strip, and each of the plurality of anchors 44 is planar. However, the elongated member 42 and the anchors 44 may be individually or in combination adopted or provided with any other suitable configuration.

[0017] exist Figure 2A-2CIn the illustrated embodiment, the elongated member 42 and the plurality of anchors 44 are formed as an integral piece, but may alternatively be separate components attached to one another. In this regard, the retainer 40 including the elongated member 42 and the anchors 44 may be formed by injection molding, extrusion and die cutting, or by stamping or cutting (e.g., laser cutting) from a sheet. The elongated member 42 is also configured or arranged to be attached to the trim cover 36. In this regard, the elongated member 42 may be sewn or stitched to the trim cover 36, but other known attachment devices or methods may alternatively be employed. The elongated member 42 with the anchors 44 may also be cut to any length suitable or necessary for use in a particular application or environment in which the component 36 is secured to the cushion 30 as described herein.

[0018] Each of the plurality of anchors 44 extends from the elongated member 42. Each of the plurality of anchors 44 has a body 46 having a first end 48 attached to the elongated member 42 and a second end 50 opposite the first end 48. The second end 50 terminates in a pointed tip. Each of the plurality of anchors 44 has a plurality of barbs 52, each barb 52 extending from the body 46 in a direction away from the tip at the second end 50 of the anchor 44. For each of the plurality of anchors 44, when the anchor 44 is inserted into the liner 30, the material of the liner 30 is clamped between the body 46 and each of the plurality of barbs 52 (see FIG. 1 ). Figure 4 In this regard, the pointed tip at the second end 50 of each anchor 44 may be used or function to penetrate or otherwise penetrate the material of the liner 30 .

[0019] It should be noted that Figure 2A-2C The anchor 44 shown in FIG. 4 including the barb 52 is exemplary only and may generally take or be provided in any shape. Figure 2A The anchor 44 shown in FIG. 1 is provided with a shape that can be described as an inverted "Christmas tree", while Figure 2C The anchor 44 shown in FIG. 1 is provided with a shape that can be described as a "ship anchor". In this regard, Figure 3 is a side view of a non-limiting exemplary embodiment of a retainer 40 according to the present disclosure. More specifically, Figure 2A 4 is a side view of an embodiment of a retainer 40 having a single anchor 44 in the shape of an inverted "Christmas tree."

[0020] In this regard, the size and shape of each anchor 44 extending from the elongated member 42 may vary. For example, the shape of the anchor 44 extending from the elongated member 42 may be different in size and shape. Figure 2A and Figure 2CThe illustrated inverted "Christmas tree" alternates between an "anchor". In addition, while shown as being equally spaced along the length of the elongated member 42, the distance between adjacent anchors 44 may be different and may vary. Likewise, the number of anchors per unit length of the elongated member 42 (i.e., density) may also vary.

[0021] It should also be noted that the anchor 44 may generally be of any size. In this regard, an anchor 44 having a second end 50 terminating in a pointed end having a sharp or acute angle and having a smaller cross-sectional area (for a cross-sectional area taken through the body 46 of the anchor 44 in a direction parallel to the elongated member 42) requires less force to insert the anchor 44 into the material of the liner 30 than an anchor 44 having a second end 50 terminating in a pointed end having a larger angle and having a larger cross-sectional area. Thus, Figure 2C The anchor 44 of the illustrated embodiment generally requires application of a Figure 2A and Figure 2B The anchor 44 of the illustrated embodiment requires greater force to be inserted into the liner 30 .

[0022] It should be further noted that Figure 2A-2C The number of barbs 52 shown for each of the anchors 44 is also merely exemplary, and any number of barbs 52 may be provided. Furthermore, the number of barbs 52 on each side of the anchor 44 may be different, the barbs 52 on each side of the anchor 44 need not be positioned directly across (i.e., mirror images) from one another, the barbs 52 along the body 46 need not be equally spaced from one another, and each barb 52 may take on or be provided with a different shape. In this regard, the larger the size and / or greater the number of barbs 52 of the anchor 44, the more effective the anchor 44 is in gripping the material of the liner 30, and the greater the resistance of the anchor 44 to removal or withdrawal from the liner 30. Thus, Figure 2A and Figure 2C The anchor 44 of the embodiment shown in FIG. Figure 2B The anchor 44 of the embodiment shown in FIG. 5 is more resistant to removal from the liner 30 .

[0023] However, it should be noted that the optimal size and shape of the anchors 44, including the barbs 52, may depend on the properties of the material of the liner 30. In this regard, for a liner 30 comprising a three-dimensional mesh structure formed from randomly looped and bonded filaments 60 of one or more extruded polymer materials as described above, the manufacturing process may result in a liner 30 having a material with larger or smaller cell structures. Figure 2A-2C The size and shape of one or more of the anchors 44 shown in , or anchors 44 having sizes or shapes different than those shown, may be best suited for a particular liner 30 material.

[0024] Figure 4 4 is another side view of a non-limiting exemplary embodiment of a retainer 40 according to the present disclosure. As seen in the figure, Figure 2A The embodiment of the retainer 40 of FIG. 4 has a single anchor 44 in the shape of an inverted "Christmas tree" and the retainer 40 is partially disposed in the material of the cushion 30. More specifically, the anchor 44 of the retainer is shown in phantom as being inserted into the material of the cushion 30, with the elongated member 42 located at the surface of the cushion 30. As previously described, the elongated member 42 of the retainer 40 can first be sewn or stitched to the decorative cover 36. The anchor 44 of the retainer 40 is then inserted into the material of the cushion 30. In this manner, the decorative cover 36 is thereby attached to the cushion 30.

[0025] Thus, the retainer 40 of the present disclosure may replace known mechanisms, devices, systems, apparatuses or methods for attaching a trim cover 36 to a cushion 30, such as a conventional polyurethane foam cushion, including clips that attach to the trim cover 36 and are configured to cooperate with beaded Duon® attachment features, hog rings and wire fasteners of the cushion 30 and / or any known attachment system that includes attachment features or fasteners molded or formed into the cushion 30. In this regard, it should be noted that the retainer 40 of the present disclosure need not be formed or molded into the material of the cushion 30. It should also be noted that the retainer 40 of the present disclosure facilitates and / or enables attachment of the trim cover 36 to a cushion 30, such as a cushion 30 having a three-dimensional reticular structure formed of randomly looped and bonded filaments 60 of one or more extruded polymer materials as described above, which cushion 30 does not include one or more recesses disposed, formed or created in the cushion for receiving a plurality of anchors 44. However, the retainer 40 of the present disclosure is also suitable for attaching a trim cover 36 to a cushion 30 that includes one or more recesses, such as elongated channels, holes, notches or grooves disposed, formed or created in the cushion for receiving a plurality of anchors 44, the one or more recesses being disposed in any suitable location, such as where the side bolster 32 meets the central seating portion 34 of the cushion 30 (see FIG. Figure 1 ).

[0026] In this regard, Figure 4As shown, the cushion 30 includes a three-dimensional mesh structure formed by randomly looped and bonded filaments 60, only a few examples of which are shown, and for simplicity, the filaments are illustrated by randomly drawn lines. As previously described, the second end 50 of the anchor 44 terminates in a pointed end, and a plurality of barbs 52 extend from the body 46 in a direction away from the pointed end of the anchor 44, and the pointed end of the anchor 44 can be used to penetrate or function to penetrate the material of the cushion 30. As also previously described, when the anchor 44 is inserted into the cushion 30, the material of the cushion 30 (i.e., the looped and bonded filaments 60) is clamped between the body 46 and each of the plurality of barbs 52. Thus, the retainer 40 of the present disclosure provides a trim retainer that is designed to snap into the material of the cushion 30, such as the strands or filaments of a non-foam mesh cushion or pad. The retainer 40 of the present disclosure also provides a barb or barb attachment to enable or aid in adhering the trim cover 36 to the cushion 30 , such as strands or wires of a non-foam mesh cushion or pad.

[0027] Next reference Figure 5 , an exemplary flow chart illustrating a non-limiting exemplary embodiment of a method 70 according to the present disclosure is shown. As seen in the figure, and with continued reference to Figure 1-Figure 4 The method 70 of assembling a seat assembly includes providing a retainer 40 at 72, the retainer 40 having an elongated member 42 and a plurality of anchors 44 extending from the elongated member 42, wherein each of the plurality of anchors 44 has a body 46 having a first end 48 attached to the elongated member 42 and a second end 50 opposite the first end 48, the second end 50 terminating in a pointed tip, and wherein each of the plurality of anchors 44 has a plurality of barbs 52, each barb 52 extending from the body 46 in a direction away from the tip. The method also includes attaching the elongated member 42 to the trim cover 36 at 74, and inserting the plurality of anchors 44 into the cushion 30 at 76, wherein for each of the plurality of anchors 44, material of the cushion 44 is clamped between the plurality of barbs 52 and the body 46.

[0028] According to the assembly method 70 of the present disclosure, inserting the plurality of anchors 44 into the cushion 30 at 76 may include piercing the material of the cushion 30 with the distal end of each anchor 44 at 78. As previously described, the elongated member 42 may include a planar strip, and attaching the elongated member 42 to the trim cover 36 at 74 may include sewing or stitching the elongated member 42 to the trim cover 36 at 80.

[0029] Again, according to the method 70 of the present disclosure, the plurality of anchors 44 can be spaced apart along the elongated member 42 with equal distances between adjacent anchors 44, but alternative spacing of the anchors 44 can be provided as previously described. Also as previously described, the elongated member 42 and the plurality of anchors 44 can be or can be formed as a unitary piece.

[0030] The assembly method 70 of the present disclosure may further include providing a cushion 30 at 82, the cushion 30 being a three-dimensional mesh structure formed of looped and bonded filaments, as previously described. Also as previously described, such filaments may be extruded and formed into a three-dimensional mesh structure. In addition, the assembly method 70 of the present disclosure also facilitates attaching a decorative cover 36 to the cushion 30 and / or enables attaching a decorative cover 36 to a cushion 30 (such as a cushion 30 having a three-dimensional mesh structure formed of randomly looped and bonded filaments 60 of one or more extruded polymer materials as described above), the cushion 30 not including one or more recesses formed in the cushion for receiving a plurality of anchors 44. However, the retainer 40 of the present disclosure is also suitable for attaching a decorative cover 36 to a cushion 30 that includes one or more recesses disposed, formed, or generated in the cushion.

[0031] Item 1: According to an embodiment, the present disclosure provides a retainer, comprising: an elongated member attached to a decorative cover; and a plurality of anchors extending from the elongated member, wherein each of the plurality of anchors has a body having a first end attached to the elongated member and a second end opposite to the first end, the second end terminating in a pointed end, and wherein each of the plurality of anchors has a plurality of barbs, each barb extending from the body in a direction away from the end; wherein, for each of the plurality of anchors, when the anchor is inserted into a pad, the material of the pad is clamped between the body and each of the plurality of barbs.

[0032] Item 2: In another embodiment, the present disclosure provides a retainer according to Item 1, wherein the elongated member comprises a planar strip.

[0033] Item 3: In another embodiment, the present disclosure provides a retainer according to any one of items 1-2, wherein each of the plurality of anchors is planar.

[0034] Item 4: In another embodiment, the present disclosure provides a retainer according to any one of items 1-3, wherein the elongated member is sewn to the trim cover.

[0035] Item 5: In another embodiment, the present disclosure provides a retainer according to any one of items 1-4, wherein the plurality of anchors are spaced apart along the elongated member, and the distances between adjacent anchors are equal.

[0036] Item 6: In another embodiment, the present disclosure provides a retainer according to any one of items 1-5, wherein the elongated member and the plurality of anchors are formed as a single piece.

[0037] Item 7: In another embodiment, the present disclosure provides a retainer according to any one of items 1-6, wherein the retainer is formed by injection molding, or by stamping or cutting from a sheet.

[0038] Item 8: In another embodiment, the present disclosure provides a retainer according to any one of items 1-7, wherein the pointed tip penetrates the cushion material.

[0039] Item 9: In another embodiment, the present disclosure provides a retainer according to any one of items 1-8, wherein the material of the pad includes a mesh formed of looped and bonded wires.

[0040] Item 10: In another embodiment, the present disclosure provides a retainer according to Item 9, wherein the wire is extruded and formed into a three-dimensional structure.

[0041] Item 11: In another embodiment, the present disclosure provides a retainer according to any one of items 1-10, wherein the material of the liner does not include formed recesses for receiving the plurality of anchors.

[0042] Item 12: In another embodiment, the present disclosure provides a seat assembly comprising: a cushion; a trim cover; and a retainer according to any one of Items 1-11, wherein the retainer attaches the trim cover to the cushion.

[0043] Item 13: According to an embodiment, the present disclosure provides a method for assembling a seat assembly, the method comprising: providing a retainer having an elongated member and a plurality of anchors extending from the elongated member, wherein each of the plurality of anchors has a body having a first end attached to the elongated member and a second end opposite to the first end, the second end terminating in a pointed end, and wherein each of the plurality of anchors has a plurality of barbs, each barb extending from the body in a direction away from the end; attaching the elongated member to a decorative cover; and inserting the plurality of anchors into a cushion, wherein, for each of the plurality of anchors, the material of the cushion is clamped between the plurality of barbs and the body.

[0044] Item 14: In another embodiment, the present disclosure provides a method according to Item 13, wherein inserting the plurality of anchors into a liner comprises piercing the material of the liner with the tip of each anchor.

[0045] Item 15: In another embodiment, the present disclosure provides a method according to any of items 13-14, wherein the elongated member comprises a planar strip, and attaching the elongated member to the trim cover comprises sewing the elongated member to the trim cover.

[0046] Item 16: In another embodiment, the present disclosure provides a method according to any one of Items 13-15, wherein the plurality of anchors are spaced apart along the elongated member, and the distances between adjacent anchors are equal.

[0047] Item 17: In another embodiment, the present disclosure provides a method according to any one of items 13-16, wherein the elongated member and the plurality of anchors are a unitary piece.

[0048] Item 18: In another embodiment, the present disclosure provides a method according to any one of Items 13-17, further comprising providing a pad, wherein the pad is a three-dimensional mesh structure formed by looped and bonded wires.

[0049] Item 19: In another embodiment, the present disclosure provides the method according to Item 18, wherein the filaments are extruded and formed into the three-dimensional mesh structure.

[0050] Item 20: In another embodiment, the present disclosure provides a method according to any one of items 13-19, wherein the material of the liner does not include formed recesses for receiving the plurality of anchors.

[0051] 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 the specification are descriptive rather than restrictive, and it should be understood that multiple changes can be made without departing from the spirit and scope of the present disclosure. In addition, unless the context clearly indicates otherwise, the various features, elements, components, methods, processes, steps and / or functions of the various embodiments of implementation can be combined or utilized in any one or more combinations, and / or can be performed in any order other than the order specifically described herein to form other embodiments according to the present disclosure. Appendix A

[0052] System and method for making mesh pads Technical Field

[0053] The present application relates to a system and method for manufacturing a mesh cushion, such as a mesh cushion for a seat. background

[0054] A three-dimensional wire connection structure manufacturing device is disclosed in US Pat. No. 10,806,272. Overview

[0055] In at least one embodiment, a method for manufacturing a mesh gasket is provided. The method may include extruding a material through a plurality of filament forming openings in a template to form a plurality of filaments. The filaments may be deposited on a first roller and a second roller. The first roller may rotate about a first axis and may define a first recess. The second roller may rotate about a second axis and may define a second recess. The first roller and the second roller may rotate to guide the filament into the first recess and the second recess and through a gap between the first roller and the second roller, thereby forming the filament into a mesh gasket having a variable cross-sectional shape.

[0056] The first roller and the second roller may be spaced apart from the template and may be positioned below the template.

[0057] The filament may be deposited while the first roller and the second roller are rotating.

[0058] The first recess and the second recess may not have mirror symmetry.

[0059] The first roller may include a first central portion and a first end plate. The first recess may extend from the first central portion. The first end plate may rotate with the first central portion about a first axis. The first end plate may extend further from the first axis than the first central portion. The first end plate may overlap with the second roller portion to guide the wire into a gap between the first roller and the second roller.

[0060] The second roller may include a second central portion and a second end plate. The second recess may extend from the second central portion. The second end plate may rotate with the second central portion about the second axis. The second end plate may extend further from the second axis than the second central portion. The second end plate may overlap the first roller portion to guide the wire into the gap between the first roller and the second roller.

[0061] The first end plate of the first roller and the second end plate of the second roller may partially overlap each other to guide the wire into the gap.

[0062] At least a portion of the first roller and the second roller may be positioned above a funnel, the funnel defining a funnel opening through which material may pass.

[0063] The filament extruded through the die plate can be provided to a chamber defined in part by a housing extending between the die plate and the hopper. The first roller and the second roller can be at least partially housed in the chamber.

[0064] The environmental control subsystem can control the temperature and humidity of the air in the chamber to control the thickness of the wire. The environmental control subsystem can be mounted to the housing. The environmental control subsystem can maintain the air temperature in the chamber within a predetermined temperature range. The predetermined temperature range can be no more than 10°F lower than the melting temperature of the material.

[0065] A method of making a mesh liner may include extruding a material through a plurality of filament forming openings in a template to form a plurality of filaments. The filaments may be directed into a funnel to consolidate and join the filaments. The filaments may then be deposited into a mold. The mold may be at least partially immersed in a fluid to cool and harden the filaments into the mesh liner.

[0066] The mold can be disposed on a conveyor. The conveyor can move or lower the mold into the fluid.

[0067] The mold may be partially contained in the fluid while the filament is being deposited.

[0068] The filament extruded through the die plate may be provided to a chamber comprising a housing and extending between the die plate and the funnel.

[0069] A method of manufacturing a mesh cushion may include providing a die set including a first die set and a second die set disposed adjacent to each other. Material may be extruded through a first set of filament forming openings in the first die set and a second set of filament forming openings in the second die set to form a plurality of filaments. The relative position of the second die set relative to the first die set may be changed so that the second die set prevents material from passing through some members of the first set of filament forming openings, thereby reducing the number of filaments formed by the die set. The filaments formed by the die set may be immersed in a fluid to cool and harden the filaments into the mesh cushion.

[0070] The second set of filament forming openings may have fewer members than the first set of filament forming openings.

[0071] The second template can be movable between a first position and a second position. When the template is in the first position and the second position, the second template can allow material to pass through some of the members of the first set of wire-forming openings.

[0072] At least one member of the second set of wire forming openings may be larger than members of the first set of wire forming openings to allow material to flow through the members of the first set of wire forming openings when the second template is in the first position and the second position.

[0073] Prior to submerging the wires, the wires may be directed into a funnel to consolidate and join the wires.

[0074] A method of manufacturing a mesh cushion may include extruding a material through a plurality of filament forming openings in a template to form a plurality of filaments. The template may be coupled to a robotic manipulator configured to move the template along a plurality of axes. The filaments may be deposited into a mold. The mold may be at least partially immersed in a fluid to cool and harden the filaments, thereby forming the filaments into the mesh cushion. The robotic manipulator may move the template while depositing the filaments to change the filament density of the mesh cushion.

[0075] The material may be extruded through the plurality of filament-forming openings at a substantially constant flow rate.

[0076] As the filament reaches and is deposited in the mold, a robotic manipulator can move the template away from the mold to reduce the diameter of the filament.

[0077] As the filament reaches and is deposited in the mold, a robotic manipulator can move the template toward the mold to increase the diameter of the filament.

[0078] The robotic manipulator can repeatedly move the template toward the mold, and then away from the mold, to vary the filament density.

[0079] The robotic manipulator may move the template in the horizontal plane at a faster speed to decrease the filament density and at a slower speed to increase the filament density. BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Figure 1 is a schematic diagram of an example of a system for making a mesh liner.

[0081] Figure 2 is Figure 1 A plan view of a portion of the system taken below the template and above the rollers that may be provided with the system.

[0082] Figure 3 is a schematic diagram of a second example of a system for making a mesh liner.

[0083] Figure 4 is a schematic diagram of a third example of a system for manufacturing a mesh liner.

[0084] Figure 5 A and Figure 5 B shows examples of wires of different sizes.

[0085] FIG. 6A and FIG. 6B are diagrams that can be used with Figures 1 to 4 Examples of templates provided with any associated system.

[0086] FIG. 7 is a side view showing the stacked template.

[0087] 8A and 8B are plan views of stacked templates in a first position and a second position, respectively. Detailed Description

[0088] 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 implemented in different and alternative forms. The drawings are not necessarily to scale; some features may be enlarged or reduced in order to show details of particular components. Therefore, the specific structural 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 adopt the present invention in different ways.

[0089] In the following description, when referring to terms defining absolute positions (such as terms "front", "rear", "top", "bottom", "left", "right", etc.) or relative positions (such as terms "above", "under", "upper", "lower", etc.) or terms defining directions (such as terms "horizontal", "vertical", etc.), it refers to the orientation of the drawings. Unless otherwise specified, the words "approximately", "substantially" and "approximately" mean deviations within 10%, preferably within 5%.

[0090] refer to Figure 1 , shows an example of a system 10 for manufacturing a mesh liner 12. The system may include an extruder subsystem 20, an environmental control subsystem 22, a material handling subsystem 24, and a control subsystem 26.

[0091] The extruder subsystem 20 can be configured to extrude the material 30 into a filament 32. In at least one configuration, the extruder subsystem 20 can include a container 40, a feeder 42, a manifold 44, and an extruder 46. The extruder subsystem 20 can also include a first roller 50, a second roller 52, and a roller drive unit 54.

[0092] The container 40 can contain and store a plurality of pieces of the material 30 to be extruded. For example, the container 40 can be configured as a hopper that can hold beads, granules, flakes, pellets, or powder made of the material 30. The material 30 can be a polymer material such as polyester or polyethylene. The container 40 can be mounted directly to the feeder 42 or positioned away from the feeder 42.

[0093] The feeder 42 can receive the material 30 from the container 40. The feeder 42 can gradually melt the material and convey the material to the manifold 44. The feeder 42 can have any suitable configuration. For example, the feeder 42 can include a barrel that can receive a rotatable screw. The rotation of the screw can force the material 30 to move through the barrel and can help heat the material 30 due to the friction generated when the screw rotates. A heating element such as a thermocouple can be disposed near the barrel and can provide thermal energy that can heat the barrel and the material 30. Optionally, the heating element can be arranged to provide a heating profile with multiple regions in which the temperature of the material 30 gradually increases as the material travels through the barrel. If too much heat is generated, a cooling device can also be provided to help keep the temperature below a predetermined value. The material 30 can leave the feeder 42 in a molten plastic state.

[0094] The manifold 44 may receive the molten material 30 under pressure from the feeder 42. The manifold 44 may direct the material 30 from the feeder 42 to the extruder 46.

[0095] The extruder 46 can extrude the material 30 into the filament 32. The extruder 46 can have any suitable configuration. For example, the extruder 46 can include one or more die plates 60, a housing 62, and a hopper 64.

[0096] One or more die plates 60 may be provided, which may include a plurality of filament forming openings 70. The filament forming openings 70 may be small through holes that may be spaced apart from one another and may be sized to create back pressure in the manifold 44 and the cartridge. The material 30 provided by the manifold 44 may pass through the filament forming openings 70 (i.e., be extruded from the die plates 60) under pressure, thereby forming the filament 32. A filament may be formed from each filament forming opening 70 through which the material 30 passes under pressure.

[0097] The housing 62 can receive and support the template 60. In addition, the housing 62 can extend between the template 60 and the funnel 64. The housing 62 can cooperate with the template 60 and the funnel 64 to completely or partially define the chamber 80. The chamber 80 can be disposed below the template 60 and above the funnel 64. In this way, the filament 32 formed by the template 60 or extruded through the template 60 can be provided to the chamber 80. The chamber 80 can be an enclosed area that is at least partially separated or isolated from the surrounding environment. Figure 1 , Figure 3 and Figure 4 8, the side of the housing 62 closest to the viewer from the perspective shown is omitted to better illustrate the features inside the housing 62. The environmental control subsystem 22 can help control the environment in the chamber 80, as will be discussed in more detail below.

[0098] The funnel 64, if provided, may be disposed near the bottom of the shell 62. The funnel 64 may define a funnel opening 90 through which the material 30 or a mesh pad 12 made from the material 30 may pass. The funnel opening 90 may have a smaller width or extend along a shorter distance than the extent to which the filament forming opening 70 extends along the template 60. Thus, the funnel opening 90 may help consolidate or condense the filament 32 in one or more configurations. In at least one configuration, the funnel 64 may extend into a fluid provided by the material handling subsystem 24, which may help isolate the chamber 80 from the surrounding air and ambient environment. It is also contemplated that the funnel 64 may be omitted in one or more configurations. It is also contemplated that if the funnel 64 is omitted, the shell 62 may extend into the fluid in the material handling subsystem 24. In Figure 1 In the configuration shown, the hopper 64 receives the material 30 that has passed between and been formed by the first and second rollers 50 , 52 .

[0099] The first roller 50 can be positioned between the template 60 and the funnel 64. For example, the first roller 50 can be positioned below the template 60 and can be spaced apart from the template 60. At least a portion of the first roller 50 can be disposed above the funnel 64 and can be spaced apart from the funnel 64. Thus, the first roller 50 can be at least partially contained in the chamber 80. The first roller 50 can rotate about a first axis 100. In at least one configuration and as best shown in FIG. 2 , the first roller 50 can have a first central portion 110, at least one recess 112, one or more end plates 114, or a combination thereof.

[0100] The first central portion 110 can extend around or encircle the first axis 100. In at least one configuration, the first central portion 110 can be disposed at a constant or substantially constant radial distance from the first axis 100. The first central portion 110 can be positioned above the funnel 64.

[0101] At least one recess 112 may extend from the first central portion 110 toward the first axis 100. In the illustrated configuration, a single recess 112 is shown; however, it is contemplated that a plurality of recesses may be provided. Furthermore, the plurality of recesses may be spaced apart from one another.

[0102] The first roller 50 can be provided with one or more end plates 114. In the illustrated configuration, two end plates 114 are shown, which are disposed near opposite ends of the first central portion 110. The end plates 114 can rotate with the first central portion 110 about the first axis 100. In addition, the end plates 114 can extend further from the first axis 100 than the first central portion 110. The end plates 114 can help contain the wire 32 so that the wire 32 does not roll off one end of the first roller 50, and can help guide the wire 32 into the gap 116 located between the first roller 50 and the second roller 52. The size and configuration of the gap 116 can change as the first roller 50 and the second roller 52 rotate.

[0103] refer to Figure 1 2 , the second roller 52 can be generally aligned with the first roller 50. Thus, the second roller 52 can be positioned between the template 60 and the funnel 64, and can be positioned below the template 60 and can be spaced apart from the template 60. At least a portion of the second roller 52 can be disposed above the funnel 64. Thus, the second roller 52 can be at least partially contained in the chamber 80. The second roller 52 can rotate about the second axis 100 '. In at least one configuration and as best shown in FIG. 2 , the second roller 52 can have a second central portion 110 ', at least one recess 112 ', one or more end plates 114 ', or a combination thereof.

[0104] The second central portion 110' can extend around or surround the second axis 100'. In at least one configuration, the second central portion 110' can be disposed at a constant or substantially constant radial distance from the second axis 100'. The second central portion 110' can be positioned above the funnel 64.

[0105] At least one recess 112' may extend from the second central portion 110' toward the second axis 100'. In the illustrated configuration, a single recess 112' is shown; however, it is contemplated that a plurality of recesses may be provided and the recesses may be spaced apart from one another. In at least one configuration, the recess 112' provided with the second roller 52 may not have mirror symmetry with a corresponding recess provided with the first roller 50, thereby allowing the mesh cushion to be formed around opposing sides having different configurations.

[0106] The second roller 52 can be provided with one or more end plates 114'. In the illustrated configuration, two end plates 114' are shown, and the end plates 114' are disposed near opposite ends of the second center portion 110'. The end plates 114' can rotate with the second center portion 110' about the second axis 100'. In addition, the end plates 114' can extend further from the second axis 100' than the second center portion 110'. The end plates 114' can help contain the wire 32 so that the wire 32 does not roll off one end of the second roller 52, and can help guide the wire 32 into the gap 116.

[0107] The end plate 114 provided by the first roller 50 can engage with and partially overlap an adjacent end plate 114' provided by the second roller 52 to help guide the wire 32 into the gap 116. In addition, the end plate can overlap with a portion of the roller to which the end plate is not attached. For example, the end plate 114 provided on the first roller 50 can partially overlap with the second roller 52 to help guide the wire into the gap 116. Additionally or alternatively, the end plate 114 provided with the first roller 50 can have an outer circumference or outer surface facing away from the first axis 100, which is closer to the second axis 100' than the second center portion 110' is disposed relative to the second axis 100. The end plate 114' provided with the second roller 52 can have an outer circumference or outer surface facing away from the second axis 100', which is closer to the first axis 100 than the first center portion 110 is disposed relative to the first axis 100. The end plates 114, 114' may be received inside the funnel 64 or may be disposed outside the funnel 64. The outer circumference or outer surface of the end plates 114, 114' may or may not be located above the funnel 64.

[0108] The roller driving unit 54 may be configured to rotate the first roller 50 and the second roller 52. For example, the roller driving unit 54 may rotate the first roller 50 and the second roller 52 in opposite directions around their respective axes. Figure 1 , the first roller 50 shown can rotate in a clockwise direction about the first axis 100 from the perspective shown, while the second roller 52 can rotate in a counterclockwise direction about the second axis 100' from the perspective shown, as represented by the curved arrow line. In addition, the roller drive unit 54 can synchronize the rotation of the first roller 50 and the second roller 52 so that the recesses 112 of the first roller 50 are aligned with the recesses 112' of the second roller 52 during each rotation of the rollers, thereby allowing the opposite sides of the mesh liner 12 to be formed with a desired cross-section at each point along its length. Improper roller synchronization may result in misaligned recesses and an improperly formed mesh liner 12.

[0109] Note that the first roller 50, the second roller 52 and the roller drive unit 54 may be omitted in various extruder subassembly configurations, such as Figure 3and Figure 4 The configuration shown in .

[0110] When the first roller 50 and the second roller 52 rotate, the filament 32 can be deposited on the first roller 50 and the second roller 52. The rotation of the first roller 50 and the second roller 52 can guide the filament 32 toward the gap 116 and through the gap 116, thereby consolidating the filament 32 and placing each filament 32 in contact with one or more other filaments 32. The filament 32 can be bent or twisted in an irregular manner and in a generally non-patterned or non-repeating manner. The recesses 112, 112' can further form the filament 32 so that the filament 32 in contact with the surface of each roller defining the corresponding recess 112, 112' becomes the contour outer surface of the part. Therefore, because the cross-sectional area of ​​each roller varies due to the presence and configuration of the corresponding recess 112, 112', the first roller 50 and the second roller 52 can form the filament 32 into a mesh pad 12 having a variable cross-sectional shape.

[0111] refer to Figure 1 , the environmental control subsystem 22 can control one or more properties or characteristics of the air in the chamber 80. For example, the environmental control subsystem 22 can control the temperature of the air in the chamber 80, the humidity of the air in the chamber 80, the air flow in the chamber 80, the air recirculation in the chamber 80, the exhaust of air from the chamber 80, or a combination thereof to help control the thickness of the wire 32. In at least one configuration, the environmental control subsystem 22 can include a fan 120 and one or more temperature adjustment devices.

[0112] exist Figure 1 , Figure 3 and Figure 4 , two temperature regulating devices 122, 124 are shown; however, it is contemplated that a different number of temperature regulating devices may be provided. The temperature regulating devices may have any suitable configuration. For example, the temperature regulating devices may be configured as heat exchangers, heating elements, cooling elements, etc. As an example, the first temperature regulating device 122 may be configured to heat air, while the second temperature regulating device 124 may be configured to cool air circulated by the fan 120 from the chamber 80 through the environmental control subsystem 22 and returned to the chamber 80 and / or dehumidify the air circulated by the fan 120 from the chamber 80 through the environmental control subsystem 22 and returned to the chamber 80.

[0113] The environmental control subsystem 22 may be used to maintain the temperature of the air in the chamber 80 within a predetermined temperature range. The predetermined temperature range may be slightly below the melting temperature of the material 30. As an example, the predetermined temperature range may be no more than 10°F below the melting temperature of the material 30. Similarly, the environmental control subsystem 22 may be used to maintain the humidity of the air in the chamber 80 within a predetermined humidity range.

[0114] Components of the environmental control subsystem 22 (eg, fan 120 ) and temperature regulating devices 122 , 124 may be mounted to the housing 62 , or may be located remote from the extruder subsystem 20 and fluidly connected to the chamber 80 by any suitable conduits (eg, hoses or tubing).

[0115] The material handling subsystem 24 may receive the material 30 after the material 30 leaves the extruder subsystem 20. The material handling subsystem 24 may be provided in a variety of configurations. Figure 1 In the illustrated configuration, the material handling subsystem 24 includes a tank 130 and a conveyor 132 .

[0116] The tank 130 can receive the material 30 exiting the extruder subsystem 20. In addition, the tank 130 can contain a fluid 134, such as water. The fluid 134 can be provided in a liquid state and can be provided at a temperature significantly below the melting temperature of the material 30. Therefore, the fluid 134 can cool and harden the filaments 32 into the mesh liner 12. Therefore, the fluid 134 can cool the filaments 32 so that the filaments 32 are no longer in a viscous molten state.

[0117] The conveyor 132 can convey the mesh liner 12. In at least one configuration, the conveyor 132 or a portion thereof can be received in the tank 130 and can be at least partially submerged in the fluid 134. The length of the conveyor 132 disposed in the fluid 132 can be sufficient to provide sufficient cooling and hardening of the wire 32 for subsequent material processing operations.

[0118] exist Figure 1 In the illustrated configuration, a portion of the conveyor 132 is shown below the extruder subsystem 20 and submerged in the fluid 134. The conveyor 132 can be spaced apart from the extruder subsystem 20 and the hopper 64 so that there is enough space for the filament 32 to exit the hopper 64. The conveyor 132 can be positioned closer to the surface of the fluid 134 than shown. In addition, it is contemplated that a portion of the conveyor 132 can exit the fluid 134 to facilitate removal of the mesh liner 12 from the tank 130.

[0119] exist Figure 3 In the illustrated configuration, the material handling subsystem 24 may also include at least one die 140. The die 140 may be positioned on a belt of the conveyor 132, and the conveyor 132 may be configured to move the die 140 relative to the extruder subsystem 20. The die 140 may define a die cavity 142 into which the filament 32 may be deposited or dispensed. The die cavity 142 may be open in a direction facing upward or toward the extruder subsystem 20.

[0120] When the filament 32 is deposited into the mold cavity 142, the mold 140 may or may not be positioned in the tank 130. Figure 3 and Figure 4 , an example is shown where the die 140 is partially contained in the fluid 134 as the filament 32 is deposited into the die cavity 142. In a configuration where the extruder subsystem 20 is stationary, the conveyor 132 can advance the die 140 below and relative to the hopper 64, thereby allowing the die cavity 142 to be filled with the filament 32. The die 140 can then be lowered into the fluid 134.

[0121] The mold 140 can be lowered into the fluid 134 or at least partially immersed in the fluid 134 in a variety of ways. In the illustrated configuration, the conveyor 132 is configured to lower the mold 140 into the fluid 134. The conveyor 132 is tilted downward into the tank 130 so that as the mold 140 moves away from the funnel 64, the mold 140 is lowered into the fluid 134, thereby allowing the fluid 134 to circulate through the filament 32 and the mold cavity 142 to cool and harden the filament 32. As another example, the mold 140 can be lowered into the fluid 134 or lifted out of the fluid 134 without the use of the conveyor 132, such as by moving the mold 140 in a generally vertical direction or in a rotating loop that can move into and out of the fluid 134. It is also contemplated that, for example, during low-volume manufacturing, the conveyor 132 can be omitted and the mold 140 can be moved manually or in another manner.

[0122] exist Figure 4 In the configuration shown, the material handling subsystem 24 may be coupled to Figure 3 However, in Figure 4 , the extruder subsystem 20 is mounted to or coupled to a robotic manipulator 150 .

[0123] The robotic manipulator 150 may move along multiple axes and may have multiple degrees of freedom. For example, the robotic manipulator 150 may be configured to move the extruder subsystem 20 along a first axis 152 , a second axis 154 , and a third axis 156 .

[0124] The first axis 152 may be a vertical axis.

[0125] The second axis 154 may be a horizontal axis that may be disposed perpendicular to the first axis 152 and may extend in a left / right direction from the perspective shown.

[0126] The third axis 156 may be disposed perpendicular to the first axis 152 and the second axis 154 and may extend in a forward / rearward direction from the perspective shown.

[0127] The extruder subsystem 20 can deposit the filament 32 into the die cavity 142 while the die 140 is stationary or in motion. It is also contemplated that, for example, during low-volume manufacturing, the conveyor 132 can be omitted and the die 140 can be moved manually or in another manner. This will be discussed in more detail below. Figure 4 The configurations and their associated properties shown in .

[0128] refer to Figure 1 , the control subsystem 26 can monitor and control the operation of the system 10. For example, the control subsystem 26 can include one or more control modules or electronic controllers 200, which can monitor and / or control the operation of one or more subsystems of the system 10. For example, the controller 200 can be a microprocessor-based controller that can be electrically connected to or communicate with components of the extruder subsystem 20 (e.g., the feeder 42 and roller drive unit 54, the environmental control subsystem 22, the material handling subsystem 24, or a combination thereof). If provided, the controller 200 can also control the operation of the robotic manipulator 150. For simplicity, Figure 1 A single controller is shown in FIG; however, it is contemplated that multiple control modules or controllers or a distributed control architecture may be provided with the control subsystem 26. The control subsystem 26 is also provided with Figure 3 and Figure 4 The configurations shown in are provided together, but are omitted from these figures for clarity only.

[0129] The controller 200 may also process input signals or data from various input devices or sensors. Input devices that may be provided with the system 10 may include a temperature sensor 160 and a humidity sensor 162.

[0130] The temperature sensor 160 can provide a signal indicating the temperature of the air in the chamber 80. The temperature sensor 160 can be of any suitable type, such as a thermistor, a thermocouple, a semiconductor-based temperature sensor, an infrared sensor, etc. The temperature sensor 160 can be disposed in any suitable location. For example, the temperature sensor 160 can be disposed in the chamber 80 or can be disposed in the environmental control subsystem 22.

[0131] The humidity sensor 162 can provide a signal indicating the humidity of the air in the chamber 80. The humidity sensor 162 can be of any suitable type, such as a capacitive humidity sensor, a resistive humidity sensor, or a thermal conductivity humidity sensor. The humidity sensor 162 can be disposed in any suitable location. For example, the humidity sensor 162 can be disposed in the chamber 84 or can be disposed in the environmental control subsystem 22.

[0132] Reference again Figure 4 , the robotic manipulator 150 can be configured to move the extruder subsystem 20 to change the filament density of the mesh cushion 12. For example, the material 30 can be extruded through the filament forming openings 70 in one or more templates 60 at a substantially constant flow rate. Therefore, given a constant filament forming opening size, it can be expected that the filaments 32 have substantially the same diameter or thickness. However, the filaments 32 become thinner as the distance from the template 60 and the filament forming opening 70 increases. Reference Figure 5 A and Figure 5 B can understand this best.

[0133] exist Figure 5 In A, a portion of template 60 and an enlarged view of filament forming opening 70 are shown. Template 60 is located above surface S at a first distance Z1.

[0134] exist Figure 5 In FIG. 6B , template 60 is located at a second distance Z2 above surface S, where Z1 is less than Z2. Due to the attenuation that occurs as filament 32 extends an increased distance and material 30 is in a molten, unhardened state, filament 32 is at a second distance Z2 above surface S. Figure 5 140. The filaments 32 may be thinner or have a smaller diameter at the surface S in FIG. B. These characteristics may be used to vary the filament density of the mesh pad 12. For example, the robotic manipulator 150 may move the template 60 upward or away from the mold 140 to reduce the size, thickness, or diameter of the filaments 32 when deposited in the mold 140. Conversely, the robotic manipulator 150 may move the template 60 toward the mold 140 to increase the size, thickness, or diameter of the filaments 32 when deposited in the mold 140.

[0135] The robotic manipulator 150 may also move the template 60 while depositing the filament 32 to change the filament density in other ways. For example, the robotic manipulator 150 may repeatedly move the template 60 toward the mold 140 and then away from the mold 140 and / or reduce the travel rate of the template 60 and / or increase the stationary dwell time of the template 60 to increase the filament density. As another example, the robotic manipulator 150 may move the template 60 in a horizontal plane (i.e., along the second axis 154 and / or the third axis 156) at a faster speed or spend less time in a particular area to reduce the filament density. Conversely, the robotic manipulator 150 may move the template 60 in a horizontal plane at a slower speed or spend more time in a particular area to increase the filament density. Thus, the filament density may increase as the time spent in a particular area increases, which allows for the deposition of more filaments, and the filament density may decrease as the time spent in a particular area decreases.

[0136] It should also be noted that Figure 4 In the embodiment of the present invention, various components of the environmental control subsystem 22 and the extruder subsystem 20 may be omitted, such as the portion of the housing 62 located below the die plate 60, the hopper 64, or both.

[0137] With reference to Figures 6A to 8B, examples of extruder subsystem configurations with interchangeable die plates or multiple die plates will now be discussed. The multiple die plates may be provided with any of the previously discussed extruder subsystem configurations, such as Figure 1 , Figure 3 and Figure 4 The configuration shown in .

[0138] 6A and 6B show examples of two different templates. The templates 60, 60' have the same size and shape, but do not have the same number of filament forming openings 70. The template 60 in FIG. 6A has a greater number of filament forming openings 70 than the template 60' in FIG. 6B. Therefore, the number of filaments 32 that can be provided by the template 60 in FIG. 6A is greater than the number of filaments 32 that can be provided by the template 60' in FIG. 6B. Therefore, given a constant material flow rate and dispensing time, a lower filament density can be provided for the mesh pad 12 using the template 60' in FIG. 6B compared to the template 60 in FIG. 6A.

[0139] With reference to Figure 7, a configuration with two stacked templates is shown.Firstly, it should be noted that it is conceivable to provide more than two templates in a stacked arrangement.

[0140] The configuration of Figure 7 will be discussed primarily in the context of a first template and a second template stacked directly on top of each other. For clarity, the lower template will be referred to as the first template, and the template resting on top of the first template will be referred to as the second template; however, it is contemplated that the positioning of the first and second templates may be changed or reversed, and that additional templates may be provided.

[0141] As an example, the first template 60 can be configured as shown in Figure 6A. The first template 60 can have a first set of wire forming openings 70. In at least one configuration, the members of the first set of wire forming openings 70 can have the same configuration.

[0142] Referring to FIGS. 7 and 8A , an example of a second template 260 is shown. The second template 260 may be disposed adjacent to the first template 60 and may have a second set of wire-forming openings 270. The components of the second set of wire-forming openings 270 may or may not have the same configuration. For example, in FIG. 8A , the components of the second set of wire-forming openings 270 do not all have the same configuration. Instead, some of the wire-forming openings 270 have the same configuration as the wire-forming openings 70 of the first template 60 (represented as circles in FIG. 8A ), and some of the wire-forming openings 270 are larger than the wire-forming openings 70 in the first template 60 (represented as elongated oval slots in FIG. 8A ). It is also contemplated that the second set of wire-forming openings 270 may have fewer components than the first set of wire-forming openings 70.

[0143] The relative positioning of the second template 260 relative to the first template 60 can be adjustable to change the alignment of the filament forming openings 70, 270 relative to each other. The alignment change can be achieved by moving the first template 60 or a portion of the first template 60 relative to the second template 260, by moving the second template 260 or a portion of the second template 206 relative to the first template 60, or by moving both. As an example, the first template 60 can remain in a stationary position and the second template 260 can slide or move along the first template 60 so that the second template 260 blocks at least some of the filament forming openings 70 and the first template 60. This can be best understood by comparing Figures 8A and 8B.

[0144] 8A, the second template 260 is shown in an example of a first position. In this example, when in the first position, the second template 260 does not block any filament forming openings 70 in the first template 60. Therefore, the material 30 can be extruded through the second set of filament forming openings 270 and then through the corresponding members of the first set of filament forming openings 70 aligned with the members of the second set of filament forming openings 270 to form filaments 32.

[0145] In FIG8B , the relative positioning of the first template 60 and the second template 260 is changed compared to FIG8A . In the example in FIG8B , the first template 60 remains in the same position as in FIG8A , and the second template 260 has been moved to a second position that is different from the first position. As a result, some components of the second set of wire-forming openings 270 remain aligned with corresponding components of the first set of wire-forming openings 70 , while other components of the second set of wire-forming openings 270 are no longer aligned with components of the first set of wire-forming openings 70 . In this way, the second template 260 is positioned to prevent material from reaching and passing through components of the first set of wire-forming openings 70 .

[0146] More specifically, in the example shown, the members of the second set of filament-forming openings 270 having circular shapes are no longer aligned with any members of the first set of filament-forming openings 70, while the oblong elliptical members of the second set of filament-forming openings 270 have been repositioned but remain sufficiently aligned with corresponding members of the first set of filament-forming openings 70 to allow material 30 to extrude through the aligned filament-forming openings 70. Thus, when the second die plate 260 is in the first position and the second position, the larger members (i.e., the elliptical members) of the second set of filament-forming openings 270 may allow material 30 to flow through corresponding members of the first set of filament-forming openings 70. As a result, filament 32 is extruded when the second die plate 260 is in the first position and the second position, but the amount of filament 32 formed by the die set is reduced when the second die plate 260 is in the second position.

[0147] It is contemplated that the template may be moved in a different manner than previously described. As an example, the template may be divided into multiple pieces that may be independently moved. For example, the second template 260 may be divided into two halves, and each half of the second template 260 may be movable to selectively block or allow material 30 to flow through a subset of the first set of wire-forming openings 70.

[0148] As another example, the template may be rotatable about an axis rather than movable in a linear direction.

[0149] As another example, multiple template regions can be integrated into a single plate that can be rotated about an axis. Each template region can have a different pattern of filament-forming openings. The single plate can then be rotated about the axis to align a particular template region with another template. Thus, each template region can provide a different number of filaments when positioned adjacent to or aligned with another template.

[0150] It is also contemplated that second die plate 260 may be moved to a position where second die plate 260 blocks all members of first set of filament-forming openings 70 of first die plate 60 , thereby terminating material flow through the die plate and terminating extrusion of filament 32 .

[0151] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the present invention. Rather, these words used in this specification are illustrative 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 different implementation embodiments may be combined to form other embodiments of the present invention.

[0152] 1. A method for manufacturing a mesh liner, comprising: extruding a material through a plurality of filament-forming openings in a die plate to form a plurality of filaments; depositing the filament on a first roller and a second roller, wherein the first roller is rotatable about a first axis and defines a first recess, and the second roller is rotatable about a second axis and defines a second recess; and The first and second rollers are rotated to guide the wire into the first and second recesses and through a gap between the first and second rollers, thereby forming the wire into the mesh pad having a variable cross-sectional shape.

[0153] 2 . The method of claim 1 , wherein the first roller and the second roller are spaced apart from the template and positioned below the template.

[0154] The method of claim 1 , wherein the filament is deposited while the first roller and the second roller are rotating.

[0155] The method according to claim 1 , wherein the first recess and the second recess do not have mirror symmetry.

[0156] 5. The method of claim 1 , wherein the first roller comprises a first center portion and a first end plate, the first recess extending from the first center portion, the first end plate being rotatable about the first axis together with the first center portion and extending further from the first axis than the first center portion, wherein the first end plate partially overlaps with the second roller to guide the wire into the gap between the first roller and the second roller.

[0157] 6. The method of claim 5, wherein the second roller comprises a second center portion and a second end plate, the second recess extending from the second center portion, the second end plate being rotatable about the second axis together with the second center portion and extending further from the second axis than the second center portion, wherein the second end plate partially overlaps the first roller to guide the wire into the gap between the first roller and the second roller.

[0158] 7 . The method of claim 6 , wherein the first end plate of the first roller and the second end plate of the second roller partially overlap each other to guide the wire into the gap between the first roller and the second roller.

[0159] 8. The method of claim 1, wherein at least a portion of the first roller and the second roller are positioned above a funnel, the funnel defining a funnel opening through which the material passes.

[0160] 9. The method of claim 8, wherein the filament extruded through the die plate is provided to a chamber defined in part by a housing extending between the die plate and the funnel.

[0161] 10. The method of claim 9, wherein the first roller and the second roller are at least partially contained within the chamber.

[0162] 11. The method according to claim 9, wherein an environmental control subsystem controls the temperature and humidity of the air in the chamber to control the thickness of the wire.

[0163] 12. A method of making a mesh liner, comprising: extruding a material through a plurality of filament-forming openings in a die plate to form a plurality of filaments; directing the filaments into a funnel to consolidate and join the filaments; depositing the filaments into a mold; and The mold is at least partially immersed in a fluid to cool and harden the filaments into the mesh pad.

[0164] 13. The method of claim 12, wherein the mold is disposed on a conveyor and the conveyor moves the mold into the fluid.

[0165] 14. The method of claim 12, wherein the mold is partially contained in a fluid while the filament is deposited.

[0166] 15. The method of claim 12, wherein the filament extruded through the die plate is provided to a chamber comprising a housing extending between the die plate and the funnel.

[0167] 16. A method of making a mesh liner, comprising: extruding a material through a plurality of filament-forming openings in a template to form a plurality of filaments, wherein the template is coupled to a robotic manipulator configured to move the template along a plurality of axes; depositing the filaments into a mold; and The mold is at least partially immersed in a fluid to cool and harden the filaments to form the filaments into the mesh cushion, wherein the robotic manipulator moves the template while depositing the filaments to vary a filament density of the mesh cushion.

[0168] 17. The method of claim 16, wherein the material is extruded through the plurality of filament-forming openings at a substantially constant flow rate.

[0169] 18. The method of claim 16, wherein the robotic manipulator moves the template away from the mold to reduce the diameter of the filament as it is deposited in the mold.

[0170] 19. The method of claim 16, wherein the robotic manipulator moves the template toward the mold to increase the diameter of the filament as it is deposited in the mold.

[0171] 20. The method of claim 16, wherein the robotic manipulator moves the template in a horizontal plane at a faster speed to decrease the wire density and moves the template at a slower speed to increase the wire density. summary

[0172] A method of making a mesh liner. The method includes extruding a material through a plurality of filament forming openings in at least one die plate to form a plurality of filaments. The filaments may be at least partially immersed in a fluid to cool and harden the filaments into the mesh liner.

[0173]

[0174] Figure 1

[0175] Figure 2

[0176] Figure 3

[0177] Figure 4

[0178] Figure 5 A

[0179] Figure 5 B

[0180] Fig. 6A

[0181] Figure 6B

[0182] Figure 7

[0183] Fig. 8A

[0184] Figure 8B.

Claims

1. A retainer, comprising: an elongated member attached to the trim cover; as well as a plurality of anchors extending from the elongated member, wherein each of the plurality of anchors has a body having a first end attached to the elongated member and a second end opposite the first end, the second end terminating in a pointed tip, and wherein each of the plurality of anchors has a plurality of barbs, each barb extending from the body in a direction away from the tip; Wherein, for each anchor of the plurality of anchors, when the anchor is inserted into the liner, material of the liner is clamped between the body and each barb of the plurality of barbs.

2. The retainer according to claim 1, wherein: The elongated member comprises a planar strip.

3. A holder according to any one of the preceding claims, wherein: Each of the plurality of anchors is planar.

4. A holder according to any one of the preceding claims, wherein: The elongated member is sewn to the trim cover.

5. A holder according to any one of the preceding claims, wherein: The plurality of anchors are spaced apart along the elongated member with adjacent anchors being equidistant from one another.

6. A holder according to any one of the preceding claims, wherein: The elongated member and the plurality of anchors are formed as a unitary piece.

7. A holder according to any one of the preceding claims, wherein: The retainer is formed by injection molding, or by stamping or cutting from sheet material.

8. A holder according to any one of the preceding claims, wherein: The pointed tip penetrates the material of the pad.

9. A holder according to any one of the preceding claims, wherein: The material of the pad comprises a mesh formed from looped and bonded wires.

10. The holder according to claim 9, wherein: The filaments are extruded and formed into a three-dimensional structure.

11. A holder according to any one of the preceding claims, wherein: The material of the liner does not include formed recesses for receiving the plurality of anchors.

12. A seat assembly comprising: liner; Decorative hood; as well as A retainer as claimed in any preceding claim, wherein the retainer attaches the trim cover to the cushion.

13. A method of assembling a seat assembly, the method comprising: providing a retainer having an elongated member and a plurality of anchors extending from the elongated member, wherein each of the plurality of anchors has a body having a first end attached to the elongated member and a second end opposite the first end, the second end terminating in a pointed tip, and wherein each of the plurality of anchors has a plurality of barbs, each barb extending from the body in a direction away from the tip; attaching the elongated member to a trim cover; and The plurality of anchors are inserted into a liner, wherein, for each anchor of the plurality of anchors, material of the liner is trapped between the plurality of barbs and the body.

14. The method according to claim 13, wherein: Inserting the plurality of anchors into the liner includes penetrating the material of the liner with the distal end of each anchor.

15. A method according to any one of the preceding claims, wherein: The elongated member includes a planar strap, and attaching the elongated member to the trim cover includes sewing the elongated member to the trim cover.

16. A method according to any one of the preceding claims, wherein: The plurality of anchors are spaced apart along the elongated member with adjacent anchors being equidistant from one another.

17. A method according to any one of the preceding claims, wherein: The elongated member and the plurality of anchors are a unitary piece.

18. The method of any preceding claim, further comprising providing a cushion which is a three-dimensional mesh structure formed from looped and bonded filaments.

19. The method according to claim 18, wherein: The filaments are extruded and formed into the three-dimensional network structure.

20. A method according to any one of the preceding claims, wherein: The material of the liner does not include formed recesses for receiving the plurality of anchors.

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