Network structure and method of manufacturing

Abstract

A wire mesh structure, a method of making and forming the wire mesh structure, and a seat assembly having the wire mesh structure. The wire mesh structure may be cut by fluid jets, may be heated using fluid to promote remodeling, or both. The silk screen structure can be provided with a foldable connecting section facilitating folding of the silk screen structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of Danish Patent Application No. PA202370186, filed on April 21, 2023, which in turn claims priority to U.S. Provisional Application Serial No. 63 / 354,288, filed on June 22, 2022, U.S. Provisional Application Serial No. 63 / 355,785, filed on June 27, 2022, and U.S. Provisional Application Serial No. 63 / 356,719, filed on June 29, 2022, the disclosures of which are hereby incorporated by reference in their entirety. Technical Field

[0002] Various embodiments are directed to mesh structures, such as cushions, seat assemblies having mesh structure cushions, and one or more methods of making and forming the mesh structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 is a perspective view of an example of a seat assembly; Figure 2 is a perspective view of an example of a cushion including a wire mesh structure that may be provided with a seat assembly; Figure 3 is a schematic diagram of an example of a manufacturing system for manufacturing a filament mesh structure; Figure 4 is a perspective view of an example of a cutting system for cutting a wire mesh structure; Figure 5A-5G shows schematic side views of various cuts that may be made using the cutting system; Fig. 6A and Figure 6B shows a schematic top view of various cuts that may be made using the cutting system; Figure 7 An example of a forming system for forming a wire mesh structure is shown, wherein a forming tool is shown in a retracted position; Figure 8 Shows Figure 7 A forming system in which steam is injected onto the wire mesh structure; Fig. 9 Shows Figure 7 A forming system wherein a forming tool engages with the wire mesh structure; Fig.10 Shown after reshaping the screen structure and while the forming tool is in the retracted position Figure 7 The formation system; Fig.11is a perspective view of another example of a forming system for forming a wire mesh structure, wherein a forming tool engages the wire mesh structure to reshape the wire mesh structure; Fig.12 is a cross-sectional view taken along section line 12-12, wherein the forming tool has steam injected prior to engagement with the wire mesh structure; Fig.13 is a perspective view of another example of a forming system for forming a wire mesh structure, wherein steam is injected through a nozzle to reshape the wire mesh structure; Fig.14 is an enlarged view of a portion of a wire mesh structure showing an example of a wire before being heated and reshaped; Fig.15 yes Fig.14 an enlarged view of a portion of a wire mesh structure in FIG. 1 , showing an example of a wire after being heated and reshaped; Fig.16 is with Figure 7-Figure 13 A flow chart of a method of forming a wire mesh structure associated with the forming system configuration shown in ; Fig.17 and Fig.18 are top and side views of an example of a wire mesh structure; Fig.19 and Fig. 20 After forming Fig.17 and Fig.18 A top view and a side view of a wire mesh structure; Fig.21 and Fig. 22 After folding Fig.19 and Fig. 20 A top view and a side view of a wire mesh structure; Fig.23 yes Fig. 22 A side view of a wire mesh structure wherein a folded portion of the wire mesh structure is fixed in a folded position. 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 these specific details. In other instances, well-known methods, processes, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring aspects of the embodiments.

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

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

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

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

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

[0010] In addition, unless otherwise clearly indicated, all numerical values ​​in this specification and claims should be understood to be modified by the word "approximately" when describing the wider scope of the present invention. The term "substantially", "roughly" or "approximately" can be used in this article, and can modify the value or related characteristics disclosed or claimed. In such a case, "substantially", "roughly" or "approximately" can represent that the value or relative characteristic modified by it is within ±0%, ±0.1%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5% or ±10% of the value or relative characteristic. Practice within the stated numerical limits is usually preferred. In addition, unless explicitly stated to the contrary, for a given purpose related to the present invention, describing a group or a class of materials with suitable or preferred means that the mixing of any two or more components in the group or class can be equally suitable or preferred.

[0011] refer to Figure 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly, such as for a land vehicle (such as a car, truck, bus, etc.), or for a non-land vehicle (such as an aircraft or a boat). For example, the seat assembly 10 for a land vehicle can be shaped and sized to be used as a front driver or passenger seat, a second, third or other rear seat, and can include a bench seat, a bucket seat or other seat styles as shown. In addition, the seat assembly 10 can be a non-stowable seat or a stowable seat, and the stowable seat can be foldable and can be stowed in a cavity in the vehicle floor. In addition, the seat assembly 10 can be configured for non-vehicle applications, such as furniture.

[0012] exist Figure 1 In the illustrated configuration, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool.

[0013] The seat bottom 20 is configured to receive a seated occupant and support the pelvis and thighs of the seat occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0014] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In one or more configurations, the seat bottom frame 30 includes a panel, a seat pan, a suspension mat, or a suspension wire on which the cushion 32 is disposed.

[0015] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a flexible material that supports the seat occupant and distributes load forces from the seat occupant to the seat bottom frame 30. The cushion 32 and associated manufacturing methods will be discussed in more detail below.

[0016] The decorative cover 34 covers at least a portion of the cushion 32. In addition, the decorative cover 34 provides one or more visible outer surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can rest on the decorative cover 34. The decorative cover 34 is made of any suitable material or materials (such as fabric, leather, artificial leather, vinyl material or a combination thereof). The decorative cover 34 may include a plurality of decorative panels assembled in any suitable manner (such as by fusing or sewing). The decorative cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the decorative cover 34 may include a decorative attachment feature that is attached to the seat bottom frame 30, the cushion 32, or both to inhibit the removal of the decorative cover 34 and help the decorative cover 34 conform to the shape of the seat bottom frame 30, the cushion 32, or both.

[0017] The seat back 22 is configured to support the back of the seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 can be disposed above the seat bottom 20 and near the rear side of the seat bottom 20. The seat back 22 extends in a generally upward direction away from the seat bottom 20. In some configurations, the seat back 22 is mounted to the seat bottom 20 and can pivot relative to the seat bottom 20. In other configurations, the seat back 22 is not mounted to the seat bottom 20. For example, a vehicle seat back can be mounted to a vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a decorative cover 44, and an optional head restraint 46.

[0018] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In one or more configurations, the seat back frame 40 includes a panel, a floor, a suspension pad, or a suspension wire on which the cushion 42 is disposed. It is also contemplated that the seat back frame 40 can be integrally formed with the seat bottom frame 30.

[0019] A cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a flexible material that supports the seat occupant and distributes load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or separate from the cushion 32 of the seat bottom 20. The cushion 42 and associated manufacturing methods will be discussed in more detail below.

[0020] The decorative cover 44 covers at least a portion of the cushion 42. In addition, the decorative cover 44 provides one or more visible outer surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can rest on the decorative cover 44. The decorative cover 44 is made of any suitable material or materials (such as fabric, leather, artificial leather, vinyl material or a combination thereof). The decorative cover 44 may include a plurality of decorative panels assembled in any suitable manner (such as by fusing or stitching). The decorative cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the decorative cover 44 may include a decorative attachment feature that is attached to the seat back frame 40, the cushion 42, or both to inhibit the removal of the decorative cover 44 and help the decorative cover 44 conform to the shape of the seat back frame 40, the cushion 42, or both.

[0021] A headrest 46, if provided, is configured to support the head of a seat occupant. The headrest 46 is disposed on a top portion of the seat back 22, or at an end of the seat back 22 disposed opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be integrally formed with the seat back 22.

[0022] refer to Figure 2 , an example of a cushion 50 is shown. For ease of reference, the cushion is generally indicated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 is applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0023] The pad 50 is a non-foam component or includes at least one non-foam component. The non-foam component is mainly called a wire mesh structure, but can also be called a twisted mesh, a mesh pad, a mesh structure or a mesh member. Figure 2 , the cushion 50 is described as a non-foam component that does not include a foam component or foam material (e.g., urethane or polyurethane foam); however, it is contemplated that the cushion 50 may include a foam component or foam material in addition to the non-foam component to provide additional cushioning or localized cushioning to the seat occupant. For example, the foam material may be disposed between the cushion 50 and a trim cover (e.g., trim cover 34, 44), on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam material provided to the cushion 50 or removing foam material from the cushion 50 may reduce weight and may improve support and comfort for the seat occupant.

[0024] The pad 50 is described below primarily in the context of the pad 50 being a non-foam component that does not include a foam material. In this case, the pad 50 is made of filaments 52 of a polymer material that are randomly bent, curled or looped and bonded together, as will be discussed in more detail below.

[0025] The filament 52 may also be referred to as a strand or line, and is made of any suitable material or materials. In some configurations, the filament 52 is made of a thermoplastic material or a plurality of thermoplastic materials, such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin, polypropylene, polystyrene, or a combination thereof. As an example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). Unlike foam materials, the filament material may be recyclable, or more easily recyclable than foam materials. It is also contemplated that the filament 52 may include reinforcing fibers, and the reinforcing fibers may not be made of thermoplastic materials.

[0026] The filaments 52 may be monofilaments made of a single material or filaments 52 made of multiple materials. For example, the filaments 52 made of multiple materials may include a core made of a first thermoplastic material and a sheath surrounding the core and made of a second thermoplastic material different from the first thermoplastic material. It is contemplated that the pad 50 may include a combination of monofilaments and filaments that are made of multiple materials and are not monofilaments.

[0027] The filaments 52 are randomly bent, looped, curled, or tangled, and may be bonded together where one filament 52 contacts another filament 52 , thereby creating a lightweight, breathable pad (e.g., pads 32 and / or 42 ) or a mesh structure having openings or voids between the filaments 52 . Fig.14 An enlarged view of an example of a filament 52 in a mesh structure is shown in . An example of a method of making a mesh pad or mesh structure is disclosed in US Patent Application No. 17 / 555,875, which is hereby incorporated by reference in its entirety. Figure 3 Also shown is an example of a manufacturing system 60 for making a cushion or mesh structure. In this example, the manufacturing system 60 includes a hopper 70, an extruder 72, a hopper 74, a tank 76, and a material handling subsystem 78.

[0028] refer to Figure 3 , a container or hopper 70 holds a raw material of material to be extruded, such as solid beads, flakes, granules, pellets or powder made of the material. The hopper 70 provides the raw material of material to the extruder 72.

[0029] The extruder 72 melts the material feedstock and extrudes the material feedstock into filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material 14 to move through the barrel and helps to heat the material due to the friction generated when the screw rotates. The material leaves the barrel under pressure and in a molten state and is transported to a die 80 of the extruder 72.

[0030] The die 80 (which may also be referred to as a die plate or extrusion die) has a plurality of through holes or filament-forming openings through which molten material passes. A single filament 52 is extruded from each through hole. The filament 52 falls downward from the die 80 into the funnel 74 under the action of gravity.

[0031] The funnel 74 consolidates or gathers the filaments 52 into a more compact arrangement, wherein the filaments 52 are bent, curled or looped, and each filament 52 contacts and is bonded to at least one other filament 52. The funnel 74 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. Individually separated filaments 52 enter the funnel inlet. When the filaments 52 accumulate, the filaments 52 are bent, curled or looped and move into contact. The filaments 52 slide downward toward the funnel outlet along the funnel 74. The bonding between the filaments 52 is formed at the contact point, and the openings or gaps between the filaments 52 exist in other positions where one filament 52 does not contact or is bonded to another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter the tank 76. For ease of reference, the bonded filaments 52 are referred to as the wire mesh structure 90.

[0032] Tank 76 holds liquid, for example water or a mixture of water and another fluid.Liquid in tank 76 helps to support the entangled and combined silk 52, further compacts or consolidates into an arrangement that is not too open or not too porous to limit silk 52, and keeps the desired porosity and density of wire mesh structure 90.Therefore, liquid provides some buoyancy or resistance, and these buoyancy or resistance can cause the extra bending, curling or looping of the silk 52 on the surface of adjacent liquid, to further build wire mesh structure 90.When silk 52 is in liquid, liquid also cools silk 52.For example, liquid cools silk 52 from outside to solidify silk 52 and prevents silk 52 from combining in an additional position.At this moment, silk 52 is relatively hard and no longer in a plastic state, and therefore usually keeps shape, and cannot be molded or reformed when not heated.

[0033] The material handling subsystem 78 transports the wire mesh structure 90 through the tank 76. The material handling subsystem 78 includes various rollers and conveyors that help move the wire mesh structure 90 through and out of the liquid. In some configurations, a traction conveyor 92 is provided in the tank 76 to help pull the wire mesh structure 90 away from the funnel 74 and counteract the buoyancy of the wire 52.

[0034] Other rollers, such as roller 94, keep the screen structure 90 submerged in the liquid and guide the screen structure 90 through the tank 76. For example, roller 94 may guide the screen structure 90 toward a conveyor belt 96 and a shaker table 98 disposed outside of the tank 76. The shaker table 98 shakes the screen structure 90 to remove the liquid while the screen structure 90 is on the conveyor belt 96. Alternatively or additionally, the screen structure 90 may be squeezed to remove the liquid, pressurized air may be blown into the screen structure 90 to remove the liquid, or both.

[0035] The manufacturing system 60 described above is a continuous flow process, wherein the wire mesh structure 90 is formed as a continuous structure when the wire extrusion is not interrupted. Further processing of the wire mesh structure 90 is provided after leaving the tank 76 to cut the wire mesh structure 90 into individual pieces for individual pads, and then provide pads 50 with desired sizes and shapes. For example, the cross-sectional shape of the wire mesh structure 90 may correspond to the shape of the funnel outlet. The manufacturing system 60 having a funnel outlet with a rectangular opening produces a wire mesh structure 90 having a generally rectangular shape or a rectangular cross section. If a pad 50 with a different shape or a different cross section is desired, then additional contouring or shaping steps are performed. For example, the wire mesh structure 90 may be cut to remove material to shape or shape the outside to provide through holes, blind holes, notches, grooves, grooves or slits or a combination thereof. The cutting, shaping and shaping of the mesh material may be accomplished using the cutting system 100.

[0036] refer to Figure 4, an example of a cutting system 100 is shown. The cutting system 100 is a fluid-based cutting system that provides a pressurized fluid to cut one or more wires 52 of the wire mesh structure 90. Therefore, the fluid is a cutting medium. The fluid is described primarily as a liquid, such as liquid water, including fluids of liquid water; however, it is contemplated that the fluid may be a gas, and it is contemplated that abrasive material may be added to the fluid as a cutting medium. In some configurations, the cutting system 100 includes a platform 110, a fluid supply subsystem 112, a cutting head 114, an automation mechanism 116, and a controller 118. The cutting system 100 may have additional fluid system components, such as filters, accumulators, vents, and the like, which are not shown for simplicity.

[0037] The platform 110 supports the wire mesh structure 90. In some configurations, the platform 110 is configured as a workbench or workstation that supports the wire mesh structure 90 in a stationary position. In other configurations, the platform 110 is a conveyor that supports the wire mesh structure 90 and is configured to move the wire mesh structure 90. The platform 110 may include a catchment device 120 that collects or receives a fluid, such as a liquid discharged or sprayed by the cutting head 114. For example, the catchment device 120 may be configured as a tray or tray provided with the platform 110 or positioned below the platform 110. The catchment device 120 may be fluidly connected to the fluid supply subsystem 112, for example when the fluid is a liquid.

[0038] The fluid supply subsystem 112 provides fluid to the cutting head 114. The fluid supply subsystem 112 includes a fluid source 130, a pump 132, and one or more fluid regulating devices 134.

[0039] The fluid source 130 contains or supplies fluid. The fluid source 130 can be pressurized or unpressurized. Examples of pressurized fluid sources include pressurized tanks, pressurized supply lines, or the like. Examples of unpressurized fluid sources are open tanks or reservoirs. In some configurations, the fluid source 130 receives fluid from the water collection device 120 to allow the fluid to be recycled or reused.

[0040] The pump 132 is fluidly connected or fluidly connectable to the fluid source 130 and the cutting head 114. The pump 132 increases the pressure of the fluid to facilitate delivery of the fluid to the cutting head 114.

[0041] One or more fluid regulators or fluid regulating devices 134 , such as valves, are provided to control the flow of fluid, such as the flow of fluid from the fluid source 130 to the cutting head 114 .

[0042] The pump 132 and fluid regulating device 134 may be controlled as described below to control the flow of fluid to the cutting head 114, such as allowing or starting fluid flow, stopping fluid flow, controlling fluid pressure, and controlling fluid flow rate.

[0043] The cutting head 114 includes a nozzle 140 that provides a jet or stream of fluid. The jet or stream of fluid is configured to cut the wire 52 when directed at the wire 52 under sufficient pressure. The jet of the stream of fluid can extend from the outlet or exit orifice of the nozzle 140 along an axis. The nozzle 140 is in fluid communication or fluidly connected to the fluid supply subsystem 112 via a conduit (such as a hose or a pipe). The cutting head 114 is mounted to an automated mechanism 116.

[0044] The automation mechanism 116 is configured to position the cutting head 114. In some configurations, the automation mechanism 116 is a robot arm, a robot manipulator, or a linear actuator. The automation mechanism 116 can be a single-axis automation mechanism, a dual-axis automation mechanism, a three-axis automation mechanism, or have more than three axes to provide greater freedom for the automation mechanism to move. For example, the automation mechanism 116 can have up to six degrees of freedom and can have a degree of freedom of movement in one or more of the following (including any combination thereof): translation in the X, Y, and Z (horizontal, vertical, and depth) directions, and rotation in the case of pitch, yaw, and roll.

[0045] The automated mechanism 116 can hold the cutting head 114 in a fixed position or move the cutting head 114 relative to the wire mesh structure 90 to facilitate cutting of the wire mesh structure 90. In one example, the automated mechanism 116 can include one or more actuators 150 configured to move the cutting head 114. For example, the actuator 150 can be configured to move the cutting head 114 along a linear path, such as when the automated mechanism 116 moves along an axis or in a plane (such as Figure 4 In other examples, the automated mechanism 116 may include one or more actuators 150 configured to move or cooperate to move the cutting head 114 in a complex path across the wire mesh structure 90, such as a non-linear path including changes in direction, a linear path, or a combination of the above paths of movement in the XY plane, and / or to move the cutting head 114 in a vertical direction or in the YZ plane toward or away from the wire mesh structure 90 for an automated mechanism with more than one degree of freedom.

[0046] In addition, the automated mechanism 116 may include additional actuators 150 that control the angle of the cutting head 114 relative to the wire mesh structure 90 and allow the cutting head 114 to rotate or tilt relative to the X-axis, Y-axis, and Z-axis or planes. Rotation or tilting of the cutting head 114 allows angled cuts relative to the XY, YZ, and XZ planes, such as chamfers, angled slits, or V-grooves.

[0047] In some configurations, the automated mechanism 116 includes at least one support member that is fixed to and extends across the wire mesh structure 90 and supports one or more actuators 150 and the cutting head 114 for movement relative thereto, such as by sliding the cutting head 114 translationally across or along the support member.

[0048] The controller 118 monitors and controls the operation of the cutting system 100. The controller 118 includes one or more controllers or control modules, which can be distributed or centralized. Some or all of the controllers can be connected via a controller area network (CAN) or other system. The controller 118 communicates with various components of the cutting system, such as the platform 110 (when configured as a conveyor), the fluid supply subsystem 112 (e.g., the pump 132 and the fluid regulating device 134), and the automation mechanism 116.

[0049] The controller 118 receives input or input signals from sensors provided with the cutting system 100, such as proximity sensors, speed sensors, pressure sensors, flow rate sensors, and the like, for controlling the cutting system 100. In addition, the controller 118 may receive input from other systems in the manufacturing process or from a user. In one example, the controller 118 receives input indicating the density of the wire mesh structure 90.

[0050] The controller 118 is configured to control the speed of the platform 110 configured as a conveyor, including stopping, starting and changing the direction of travel. As an example, when cutting, the speed of the conveyor can be stopped or reduced.

[0051] The controller 118 is configured to control the movement of the automated mechanism 116 by controlling its actuators 150 , and thereby control the position, orientation, and movement or travel speed of the cutting head 114 and nozzle 140 relative to the wire structure 90 .

[0052] The controller 118 is configured to control the flow of fluid from the nozzle 140, for example, by controlling the pump 132 and the fluid regulating device 134 to allow fluid to flow to the nozzle 140, increase the flow of fluid to the nozzle 140, decrease the flow of fluid to the nozzle 140, and stop the flow of fluid to the nozzle 140. The controller 118 is configured to increase, decrease, or maintain the pressure of the fluid provided to the nozzle 140, the flow rate of the fluid at the nozzle 140, or both.

[0053] It should be appreciated that the controller 118 or other electrical device disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., flash memory (FLASH), random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variants of these memory devices) and software, which cooperate or work together to perform the operations disclosed herein. In addition, any one or more of the electrical devices disclosed herein may be configured to execute a computer program contained in a non-transitory computer-readable medium, which is programmed to perform any number of functions disclosed herein.

[0054] The controller 118 is configured to control the speed of the cutting head 114 and the pressure and flow rate of the fluid exiting the nozzle 140 based on the thickness of the wire mesh structure 90 and the depth of the selected cut into the wire mesh structure 90. In addition, the controller 118 can control the cutting head 114 and the cutting system 100 to provide a single pass cut or to provide multiple pass cuts in which the selected cut requires multiple passes of the cutting head 114 along the cutting path.

[0055] The cutting system 100 can provide planar cuts, or cuts along a single plane aligned with or angled relative to the X, Y, and / or Z planes. The planar cuts can produce planar sides or planar surfaces of the wire mesh structure 90. In addition, the cutting system 100 can provide cutting along a single axis.

[0056] The cutting system 100 may provide a cut completely through the wire mesh structure 90 to separate the wire mesh structure into individual pieces, either using a single pass of the cutting head 114 relative to the wire mesh structure 90 , or using more than one pass of the cutting head 114 .

[0057] In addition, the cutting system 100 is controllable in a manner that provides a variable depth of cutting. The presence and position of the wire 52 changes in the wire mesh structure 90, because the wire 52 is bent, looped or otherwise shaped in various directions with a gap therebetween. Therefore, the cutting system 100 is controllable to adjust the fluid jet according to the presence, quantity, size or absence of the wire 52 at the position where the incision will be set in the wire mesh structure 90. For example, the cutting system 100 is controllable to increase the force applied by the fluid jet when cutting through multiple wires, when cutting through larger diameter wires, or in order to reach and cut the wire located at a greater depth or distance from the nozzle 140. For incisions, such as partial incisions that do not extend completely through the wire mesh structure 90, the cutting system 100 can use the cutting head 114 to operate with additional passes of lower speed, lower fluid pressure and / or lower fluid flow rate to increase the precision and / or accuracy of cutting into the wire mesh structure 90.

[0058] The cutting system 100 is configured to provide multiple types of cuts in the wire mesh structure 90. These include through cuts and partial cuts or "blind cuts" in the wire mesh structure 90. Through cuts can separate the wire mesh structure 90 into separate pieces or provide through holes or slits that do not produce separate pieces. Partial cuts do not extend completely through the wire mesh structure 90 and can be used to provide blind holes, grooves, slits, or slots. According to various examples, the cutting system 100 can be controlled to provide orthogonal cuts, bevels, fillets, radii, or the like.

[0059] Figure 5A-5G Some examples of various cuts that can be provided by cutting system 100 are shown that can be side views or cross-sectional views of a wire mesh structure (e.g., wire mesh structure 90). These examples are not exhaustive. In these figures, wire mesh structure 90 is represented as a rectangular block before cutting. Dashed lines are used to represent the areas that are cut away in the rectangular block.

[0060] Figure 5A An orthogonal cut 160 is shown which may create orthogonal sides or surfaces. Figure 5B An undercut fillet 162 is shown. Figure 5C Rounded corners 164 are shown. Figure 5D A chamfer 166 is shown. Figure 5E Two partial cuts to different cutting depths to form two grooves 168 are shown and may be a side view or a cross-sectional view. Fig. 5F The through slot or through hole 170 and the blind hole 172 are shown in cross-section. Figure 5GA V-shaped channel 174, which may also be referred to as a channel, recess or slot, and an angled partial cut 176 are shown and may be a side view or a cross-sectional view. The V-shaped channel 174 may also be provided with a greater depth and extend through the wire mesh structure 90. The V-shaped channel 174 or angled partial cut 176 is provided by performing two cuts (such as blind cuts) along different cutting paths that are angled relative to each other and intersect.

[0061] Fig. 6A and Figure 6B Shown are top views of wire mesh structures (eg, wire mesh structure 90) having various cuts that may be provided with cutting system 100. These examples are not exhaustive. Fig. 6A A double chamfer 178 and a groove 168 are shown, which is cut to a local depth and extends laterally across the wire mesh structure 90 . Figure 6B An example of a curved cut or curved contour 180 is shown, which may include curved sides having convex sections, concave sections, or a combination thereof. Figure 6B Also shown are examples of through holes 170 and grooves 182 that have two angled sections connected by an arcuate portion and that extend only partially across the wire mesh structure 90 and are either through cuts or partial cuts.

[0062] It should be understood that the cutting system 100 can provide cuts along various sides of the wire mesh structure 90. In addition, the cutting system 100 can provide through cuts and partial cuts along linear and non-linear paths and in three dimensions. For example, the cutting system 100 can provide a curved or contoured surface when viewed along multiple axes, such as any combination of the X-axis, the Y-axis, and the Z-axis.

[0063] The controller 118 is configured to coordinately control the movement of the automated mechanism 116 and the fluid flow and fluid pressure provided by the fluid supply subsystem 112 to the nozzle 140 to provide a desired type of cut at a desired location. In some cases, a deeper cut can be provided by controlling the automated mechanism 116 to move the cutting head 114 at a slower speed, by controlling the automated mechanism 116 to move the nozzle 140 closer to the wire mesh structure 90, by controlling the automated mechanism 116 to move the nozzle 140 along multiple or repeated cutting passes, by increasing the fluid flow to the nozzle 140, by increasing the fluid flow rate to the nozzle 140, or a combination thereof. Similarly, shallower cuts can be provided by controlling the automated mechanism 116 to move the cutting head 114 at a higher speed, by controlling the automated mechanism 116 to move the nozzle 140 away from the wire mesh structure 90, by controlling the automated mechanism 116 to move the nozzle 140 along fewer cutting passes or non-repeated cutting passes, by reducing the flow of fluid to the nozzle 140, by reducing the flow rate of fluid to the nozzle 140, or a combination thereof.

[0064] The control parameters associated with a particular type of incision can be based on experiments or modeling. For example, a wire mesh structure 90 can be manufactured using a manufacturing system 60. The associated wire parameters, such as the number of wires extruded by the die 80, the wire size (e.g., cross-sectional area), and the wire extrusion speed are recorded. Then, the density of the resulting wire mesh structure 90 is measured, for example, by hydrostatic weighing, and recorded. Then, the cutting system 100 can be used to perform sample cutting at various cutting head speeds, fluid pressures, and fluid flow rates to determine whether the combination of speed, pressure, and flow rate is sufficient to provide the desired incision in the wire mesh structure 90. The acceptable range or combination of speed, pressure, and flow rate can be recorded or stored in a memory and can be associated with the density of the wire mesh structure 90 because the density is measured in advance. Then, the acceptable range or combination is input to the controller 118 or used by the controller 118 to control the cutting system 100 based on the density of the wire mesh structure 90.

[0065] As a non-limiting example, the nozzle 140 is provided with a diameter of 8 thousandths of an inch and is operated at a distance of 5 mm to 10 mm from the wire mesh structure 90. The fluid jet is provided at a pressure in the range of 58,000 psi to 70,000 psi (399,895 kPa to 482,633 kPa) and the nozzle has a velocity in the range of 1 mm / s to 75 mm / s relative to the wire mesh structure 90. The fluid jet is provided at a density in the range of 2.7 lbs / ft3 to 3.4 lbs / ft3 (43.2 to 54.5 kg / m 3 ) range with a wire diameter of 0.5 mm. In other examples, each of the nozzle diameter, distance, nozzle speed, pressure and / or wire mesh structure 90 density or wire diameter may be greater or less than the range or value.

[0066] It is contemplated that multiple cutting systems 100, such as cutting systems arranged in parallel or in series, can be used to increase throughput. It is also contemplated that the wire mesh structure 90 can be cut using other cutting techniques, such as a mechanical cutter (such as a cutting wheel), in combination with the use of the cutting system 100 for cutting.

[0067] The method associated with the cutting system 100 is used to form cushions (e.g., cushions 32 and / or 42), and further optionally used to assemble a seat (e.g., seat assembly 10). In various examples, the method can have more or fewer steps than described below, and the various steps can be performed in another order, sequentially, or simultaneously.

[0068] The method includes cutting a wire mesh structure (eg, wire mesh structure 90 ) using a fluid jet (eg, fluid jet 150 ).

[0069] In some embodiments, a cushion (eg, cushions 32 and / or 42 ) is at least partially formed by cutting a mesh structure (eg, mesh structure 90 ) using a fluid jet (eg, fluid jet 150 ).

[0070] In some embodiments, the method includes attaching a cushion (eg, cushion 32 and / or 42 ) to a frame (eg, frame 30 and / or 40 ) of a seat assembly (eg, seat assembly 10 ).

[0071] In some embodiments, the method includes positioning a decorative cover (e.g., decorative cover 34 and / or 44) on a cushion (e.g., cushion 32 and / or 42) and attaching the decorative cover (e.g., decorative cover 34 and / or 44) to the cushion (e.g., cushion 32 and / or 42), to a frame (e.g., frame 30 and / or 40), or to the cushion (e.g., cushion 32 and / or 42) and a frame (e.g., frame 30 and / or 40).

[0072] In some embodiments, the method includes forming a mesh structure (eg, mesh structure 90 ) using filaments of thermoplastic material (eg, filaments 52 ) that are randomly looped and bonded.

[0073] In some embodiments, forming a mesh structure (eg, mesh structure 90 ) includes extruding a thermoplastic material through a die (eg, die 80 ) to form filaments (eg, filaments 52 ), and then passing the filaments (eg, filaments 52 ) through a funnel (eg, funnel 74 ).

[0074] In some embodiments, the method includes cutting the wire mesh structure (eg, wire mesh structure 90 ) after the wire (eg, wire 52 ) passes through the funnel (eg, funnel 74 ).

[0075] In some embodiments, the method includes controlling the travel speed of a cutting head (e.g., cutting head 114) to control the depth of cuts (e.g., orthogonal cuts 160, undercut fillets 162, fillets 164, chamfers 166, grooves 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved shapes 180, grooves 182) into a wire mesh structure (e.g., wire mesh structure 90).

[0076] In some embodiments, the method includes reducing the travel speed of a cutting head (e.g., cutting head 114) to increase the depth of cuts (e.g., orthogonal cuts 160, undercut fillets 162, fillets 164, chamfers 166, grooves 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved shapes 180, grooves 182) into a wire mesh structure (e.g., wire mesh structure 90).

[0077] In some embodiments, the method includes moving a cutting head (e.g., cutting head 114) proximate a wire mesh structure (e.g., wire mesh structure 90) to increase the depth of a cut (e.g., an orthogonal cut 160, an undercut fillet 162, a fillet 164, a chamfer 166, a groove 168, a through hole 170, a blind hole 172, a V-shaped channel 174, a partial cut 176, a chamfer 178, a curved shape 180, a groove 182) into the wire mesh structure (e.g., wire mesh structure 90).

[0078] In some embodiments, the method includes increasing the fluid pressure provided to a cutting head (e.g., cutting head 114) to increase the depth of a cut (e.g., an orthogonal cut 160, an undercut fillet 162, a fillet 164, a chamfer 166, a groove 168, a through hole 170, a blind hole 172, a V-shaped channel 174, a partial cut 176, a chamfer 178, a curved shape 180, a groove 182) into a wire mesh structure (e.g., wire mesh structure 90).

[0079] In some embodiments, the method includes increasing the fluid flow rate of a fluid jet (e.g., fluid jet 150) to increase the depth of a cut (e.g., orthogonal cut 160, undercut fillet 162, fillet 164, chamfer 166, groove 168, through hole 170, blind hole 172, V-shaped channel 174, partial cut 176, chamfer 178, curved shape 180, groove 182) into a wire mesh structure (e.g., wire mesh structure 90).

[0080] In some embodiments, cutting a wire mesh structure (e.g., wire mesh structure 90) using a fluid jet (e.g., fluid jet 150) includes positioning a cutting head (e.g., cutting head 114) away from the wire mesh structure (e.g., wire mesh structure 90) such that the cutting head (e.g., cutting head 114) does not contact the wire mesh structure (e.g., wire mesh structure 90).

[0081] In some embodiments, the method includes controlling an automated mechanism (eg, automated mechanism 116 ) supporting a cutting head (eg, cutting head 114 ) to move the cutting head (eg, cutting head 114 ) along a cutting path relative to a mesh structure (eg, mesh structure 90 ).

[0082] In some embodiments, the method includes controlling an automated mechanism (eg, automated mechanism 116 ) in at least one degree of freedom to move a cutting head (eg, cutting head 114 ) along a cutting path.

[0083] In some embodiments, the method includes controlling an automated mechanism (eg, automated mechanism 116 ) in at least three degrees of freedom to move a cutting head (eg, cutting head 114 ) along a cutting path.

[0084] In some embodiments, the method includes cutting completely through the wire structure 90 via a fluid jet (eg, a fluid jet mesh structure (eg, wire mesh knots 150 )).

[0085] In some embodiments, the method includes partially cutting through a mesh structure (eg, mesh structure 90 ) via a fluid jet (eg, fluid jet 150 ).

[0086] In some embodiments, the method includes cutting one or more of a planar surface and a curved shape (eg, curved shape 180 ) in a mesh structure (eg, mesh structure 90 ) via a fluid jet (eg, fluid jet 150 ).

[0087] In some embodiments, the method includes cutting one or more of orthogonal surfaces (e.g., orthogonal cuts 160 ), fillets (e.g., undercut fillets 162 , fillets 164 ), chamfers (e.g., chamfer 166 ), and grooves (e.g., groove 168 ) in a wire mesh structure (e.g., wire mesh structure 90 ) via a fluid jet (e.g., fluid jet 150 ).

[0088] refer to Figure 7 , an example of a forming system 200 for forming a wire mesh structure 90 is shown. The forming system 200 is configured to form or shape the wire mesh structure 90 without cutting or severing the wires 52 of the wire mesh structure 90. The wire mesh structure 90 can be formed or shaped using the forming system 200 alone or in combination with the cutting system 100 discussed previously.

[0089] As previously described, the manufacturing system 60 produces a wire mesh structure 90 having a particular cross-sectional shape (e.g., a rectangular cross-sectional shape). In some cases, the cross-sectional shape produced by the manufacturing system 60 does not provide a desired contour or seat pad contour. In addition, the wire 52 of the wire mesh structure 90 output from the manufacturing system 60 is cooled and hardened such that the wire 52 is relatively rigid and no longer in a plastic state and is therefore not moldable or formable. Therefore, it may be desirable to change the shape of the wire mesh structure 90 from the original cross-sectional profile of the wire mesh structure 90 (e.g., the cross-sectional profile produced by the manufacturing system 60) to provide one or more recesses, protruding areas, curved areas, and the like. As an example, the wire mesh structure 90 or a portion of the wire mesh structure 90 is heated and reformed or reshaped to provide one or more recesses 210, an example of which is shown in FIG. Fig.10 Shown in.

[0090] The recess 210 provided in the wire mesh structure 90 may be an elongated channel, hole, notch or groove. The recess 210 may be provided at any suitable position. For example, the recess 210 may be provided in the side of the wire mesh structure 90 that is configured to face the seat occupant. As some additional examples, the recess 210 may be provided where the side bolster meets the central seating portion of the wire mesh structure 90, and the recess 210 may extend across the central seating portion, such as from front to back or from one side to the other side, or a combination thereof. The recesses 210 may be spaced apart from each other or may intersect. The recess 210 may partially extend to the wire mesh structure 90 but may not completely extend through the wire mesh structure 90.

[0091] refer to Figure 7 , an example of a forming system 200 is shown. The forming system 200 includes a support surface 220, a forming tool 222, a positioning device 224, a steam subsystem 226, and a control system 228.

[0092] The support surface 220 is configured to support the wire mesh structure 90. The support surface 220 may be Figure 7 The generally flat surface shown. Alternatively, the support surface 220 can be contoured. The support surface 220 can be a fixed surface or a movable surface. It is contemplated that the support surface 220 can be part of a formed mold.

[0093] The forming tool 222 facilitates the forming or shaping of the wire mesh structure 90. More specifically, the forming tool 222 is configured to reshape the wire mesh structure 90 to change or vary the shape or cross-section of the wire mesh structure 90 at one or more locations. The forming tool 222 is mounted to a positioning device 224.

[0094] The forming tool 222 can be arranged in a variety of configurations. These configurations are broadly categorized by how the forming tool reshapes the wire 52 of the wire mesh structure 90. For example, the forming tool can reshape the wire mesh structure 90 by engaging the forming tool with the wire mesh structure 90 without engaging the forming tool with the wire mesh structure 90, or a combination thereof. Figure 7-10 as well as Fig.11 and Fig.12 , examples of forming tools 222, 222' are shown, wherein the forming tools engage at least some of the wires 52 and apply force to at least some of the wires 52 to reshape at least one wire 52 of the wire mesh structure 90. Fig.13 In the illustrated configuration, the forming tool 222 ″ does not engage the wire 52 and applies force to the wire 52 to reshape the wire mesh structure 90 . In each configuration, the forming tool 222 , 222 ′, 222 ″ includes one or more nozzles fluidly connected to the steam subsystem 226 .

[0095] refer to Figure 7-10, forming tool 222 is shown positioned above screen structure 90 and support surface 220. Figure 7 and Figure 8 In the drawings, for the sake of clarity and simplicity, the screen structure 90 is shown with a dotted pattern to represent a non-sectional view. Fig. 9 and Fig.10 , the wires of the wire mesh structure 90 are illustrated by randomly drawn lines to represent a cross-sectional view of the wire mesh structure 90 so that the recess 210 is more clearly visible. The forming tool 222 includes a tool body 230, a heater 232, one or more nozzles 234, one or more nozzle valves 236, or a combination thereof.

[0096] The tool body 230 provides the primary structure of the forming tool 222. The tool body 230 may be mounted to the positioning apparatus 224 and include or define one or more passages 240 that fluidly connect the steam subsystem 226 to the nozzle 234 and the nozzle valve 236. For example, the tool body 230 may include a manifold 242 from which the passages 240 extend. The tool body 230 has a forming side 244.

[0097] The forming side 244 faces the wire mesh structure 90 and the support surface 220. In at least one configuration, the forming side 244 includes one or more forming features 246. The forming features 246 are configured as protrusions extending toward the wire mesh structure 90, recesses extending away from the wire mesh structure 90, or a combination thereof. One or more nozzles 234 can be provided with forming features 246.

[0098] The heater 232, if provided, is configured to heat the forming side 244 of the forming tool 222. The heater 232 can have any suitable configuration. For example, the heater 232 can be configured as an electric heater or a resistive heater that circulates a heated fluid through the tool body 230 or the like. It is also contemplated that the heater 232 can be part of the steam subsystem 226. For example, steam or a heated fluid such as water can be circulated in the tool body 230 before being directed to one or more nozzles 234. The heat or thermal energy provided to the forming side 244 by the heater 232 increases the temperature of the forming feature 246, which promotes the reforming or reshaping of the wire 52, as will be discussed in more detail below.

[0099] One or more nozzles 234 are disposed on the tool body 230. The nozzles 234 are fluidly connected to the steam subsystem 226 and direct pressurized steam 248 toward the wire mesh structure 90 to heat one or more wires 52 of the wire mesh structure 90 to facilitate reforming or reshaping of the wires 52, as will be discussed in more detail below. The nozzles 234 have at least one orifice through which the steam 248 can be discharged. The one or more nozzles 234 can be provided with a forming feature 246. In Figure 7 , the nozzle 234 is shown as being disposed substantially perpendicular to the top side of the wire mesh structure 90 prior to reshaping; however, it is contemplated that the nozzle 234 may be disposed in a non-perpendicular relationship to the top side of the wire mesh structure 90, or that additional nozzles 234 or orifices may be provided that may be disposed in a non-perpendicular relationship to the top side.

[0100] The nozzle valve 236 controls flow to one or more associated nozzles 234. Figure 7 In the illustrated configuration, each nozzle valve 236 is shown as being associated with a single nozzle 234; however, it is contemplated that the nozzle valve 236 may be associated with a plurality of nozzles 234, and that some or all of the nozzles 234 may not be fluidly connected to the nozzle valve 236. In some configurations, the nozzle valve 236 is provided with or within the tool body 230. The nozzle valve 236 is actuatable between an open position and a closed position. In the open position, the nozzle valve 236 allows flow from the steam subsystem 226 through the nozzle valve 236 and to one or more associated nozzles 234. In the closed position, the nozzle valve 236 prevents flow from the steam subsystem 226 through the nozzle valve 236 and to one or more associated nozzles 234.

[0101] refer to Fig.11 and Fig.12 , another example of forming tool 222' is shown. Fig.11 In the drawings, for the sake of clarity and simplicity, the screen structure 90 is shown with a dotted pattern to represent a non-sectional view. Fig.12 , the filaments of the wire mesh structure 90 are illustrated by randomly drawn lines to represent a cross-sectional view of the wire mesh structure. A forming tool 222 ′ may be positioned above the wire mesh structure 90 and may include a tool body 230 ′, a manifold 242 ′, and one or more nozzles 234 .

[0102] The tool body 230' is fixedly positioned relative to the manifold 242', the nozzle 234, or both. In at least one configuration, the tool body 230' is spaced apart from the nozzle 234 and does not contact the nozzle 234. The tool body 230' is moved or actuated by the positioning device 224. The tool body 230' moves or actuates against the wire mesh structure 90 and at least partially enters the wire mesh structure 90 to apply pressure to reshape one or more wires 52, as will be discussed in more detail below. The tool body 230' can be configured as a wire, rod, or tube that can extend completely across or partially across the top side of the wire mesh structure 90.

[0103] The manifold 242' fluidly connects the steam subsystem 226 to the nozzles 234. For example, the manifold 242' can be configured as a tube or pipe that distributes fluid to the nozzles 234. In addition, the manifold 242' can be positioned farther from the top side of the wire mesh structure 90 than at least a portion of the tool body 230' so that the manifold 242' and / or one or more nozzles 234 do not contact or engage the wire 52 during reshaping.

[0104] One or more nozzles 234 are fluidly connected to the manifold 242'. As previously described, one or more nozzle valves 236 may optionally be provided to control the flow of fluid to the one or more nozzles 234. The nozzles 234 may be spaced apart from one another and arranged to provide steam 248 that heats the wire 52 and the tool body 230'.

[0105] refer to Fig.13 , another example of a forming tool 222'' is shown. The forming tool 222'' is again shown as being positioned above the wire mesh structure 90; however, it should be understood that the forming tool 222'' can be moved to other positions. The forming tool 222'' can include one or more nozzles 234 and nozzle valves 236 as previously described, but the tool body that can engage with the wire mesh structure 90 can be omitted.

[0106] refer to Figure 7 , positioning device 224 positions forming tool 222 relative to screen structure 90. Positioning device 224 has any suitable configuration. For example, positioning device 224 can be a linear actuator configured to move forming tool 222 linearly or along an axis, such as between a retracted position and an extended position. Figure 7 In the retracted position shown, the forming tool 222 is separated from, positioned away from, or spaced apart from the wire mesh structure 90. Fig. 9In the extended position shown, the forming tool 222 engages the wire mesh structure 90 and applies force thereto. The positioning device 224 may also be provided in other configurations. For example, the positioning device may be configured to rotate the forming tool 222 about an axis to engage or disengage the wire mesh structure 90. As another example, the positioning device may be configured to move in multiple directions or may have multiple degrees of freedom. Examples of such positioning devices are shown in Fig.13 , where the positioning device 224 ″ is configured as a robotic manipulator having multiple degrees of freedom.

[0107] The steam subsystem 226 is configured to provide steam 248 or a fluid that becomes steam 248 when discharged from the nozzle 234 to the forming tool 222. Therefore, the term "steam" includes any combination of temperature and pressure that produces steam or vaporized fluid after leaving the nozzle. The term "steam" contemplates vaporized water as well as vaporized fluids other than water, or vaporized fluids other than water. The steam subsystem 226 has any suitable configuration. In at least one configuration, the steam subsystem 226 includes a fluid source 250, a fluid heater 252, and at least one control valve 254.

[0108] Fluid source 250 is configured to hold or provide a fluid, such as liquid water, that can be converted to steam 248. Fluid source 250 is fluidly connected to fluid heater 252 and control valve 254 in any suitable manner, such as using pipes, hoses, or the like.

[0109] The fluid heater 252 is fluidly connected to the fluid source 250. The fluid heater 252 is configured to heat the liquid received from the fluid source 250 so that the fluid becomes a gas or vapor 248 when or before leaving the nozzle 234. For example, the fluid heater 252 can heat the liquid so that it becomes a gas after passing through the fluid heater 252 and before or after passing through the control valve 254.

[0110] The control valve 254 controls the flow of fluid or gas to the forming tool 222. In at least one configuration, the control valve 254 can be moved between an open position and a closed position. In the open position, the fluid or gas flows through the control valve 254 to the forming tool 222. In the closed position, the fluid or gas does not flow through the control valve 254.

[0111] The control system 228 monitors and controls the various components and subsystems of the forming system 200. For example, the control system 228 may include one or more microprocessor-based control modules or controllers 260 that may control the operation of the forming tool 222, the positioning device 224, the steam subsystem 226, or a combination thereof. Thus, the control system 228 controls the operation of the positioning device 224, the nozzle valve 236, the fluid heater 252, the control valve 254, or a combination thereof.

[0112] refer to Fig.16 , a flow chart of a method of forming a wire mesh structure 90 is shown. The method is associated with any of the previously discussed forming system configurations (e.g., the forming system 200 employs a single forming tool 222, 222', or 222" or more than one forming tool 222, 222', 222" in any combination). The flow chart covers three main method steps. The method may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0113] At block 300, the mesh structure 90 and the forming tool 222, 222', and / or 222" are aligned so that the forming tool 222, 222', and / or 222" can reshape the mesh structure 90 at one or more predetermined locations. The mesh structure 90 and the forming tool 222, 222', and / or 222" may be aligned by moving the mesh structure 90 relative to the forming tool 222, 222', and / or 222", by moving the forming tool 222, 222', and / or 222" relative to the mesh structure 90, or by moving both the mesh structure 90 and the forming tool 222, 222', and / or 222".

[0114] At block 302, the wire mesh structure 90 is formed using the forming tools 222, 222', and / or 222". The wire mesh structure 90 is formed using the forming tools 222, 222', and / or 222" by spraying steam 248 onto the wire mesh structure of the wire mesh structure 90. The steam 248 may be sprayed directly onto the wire 52 and may not pass through an intermediate steam permeable layer, such as a fabric or cloth. Spraying the steam 248 onto the wire mesh structure provides a variety of functions.

[0115] First, the steam 248 heats the filament 52 to allow the filament 52 to be reformed or reshaped. More specifically, the thermal energy provided by the steam 248 heats the thermoplastic filament 52 to a temperature that allows the thermoplastic material of the heated filament 52 to be remolded into a different shape. The thermal energy softens or plasticizes the filament 52 without melting the filament 52. Therefore, the steam 248 is provided in a manner that keeps the temperature of the filament 52 below the melting temperature of the thermoplastic material. For example, the filament 52 can be heated by the steam 248 to a temperature that is 10°C to 50°C lower than the melting temperature of the thermoplastic material. Therefore, the filament 52 is heated in such a manner that it is sufficient to allow the filament 52 to be plastically reshaped, but not sufficient to cause new bonds to be formed between one filament 52 and another filament 52 or between the filament and itself.

[0116] Second, the steam 248 provides a coating or barrier that helps prevent the filament 52 from sticking or adhering to the forming tools 222, 222', and / or 222". The coating can be a coating of a fluid or fluid droplets that accumulate on the exterior of the filament 52. The coating acts as a lubricant or barrier that is contacted by the forming tools 222, 222', and / or 222", and can prevent the filament 52 from bonding to the forming tools 222, 222', and / or 222".

[0117] Third, in some cases, steam 248 applies sufficient pressure to reshape one or more wires 52 of mesh structure 90 .

[0118] Different amounts of steam 248 may be provided to different nozzles 234 to control the reshaping of the wire mesh structure 90. For example, a first nozzle valve 236 that controls the flow of steam to a first nozzle 234 may be controlled to discharge a different amount of steam 248 than a second nozzle valve 236 that controls the flow of steam to a second nozzle 234.

[0119] At box 304, the flow of steam 248 is shut off and the position of the forming tool 222, 222' and / or 222" is reset to accommodate the reshaping of another mesh structure 90. The flow of steam 248 may be shut off before, during, or after resetting the position of the forming tool 222, 222' and / or 222". Shutting off the flow of steam 248 allows the temperature of the filament 52 to decrease so that the filament 52 cannot be remolded into a different shape without reheating.

[0120] More specific examples of method steps associated with different forming system configurations will now be described.

[0121] refer to Figure 7 , the forming tool 222 is shown in a retracted position as previously described. The wire mesh structure 90 and the forming tool 222 are aligned so that the forming tool 222 is ready to reshape the wire mesh structure 90 in one or more predetermined positions. The control valve 254, the nozzle valve 236, or both are closed so that the steam 248 is not ejected by the nozzle 234. In a configuration where the forming tool 222 includes the heater 232, the heater 232 can heat the forming tool 222 when the steam 248 is not ejected by the nozzle 234.

[0122] refer to Figure 8, steam 248 is shown being ejected from nozzle 234. Steam 248 is ejected from nozzle 234 by opening control valve 254 and one or more nozzle valves 236 (if any). Steam 248 is directed toward one or more wires 52 of wire mesh structure 90 to heat the wires 52 and help inhibit subsequent bonding of the wires 52 to forming tool 222, as previously described.

[0123] refer to Fig. 9 , the forming tool 222 is engaged with the wire mesh structure 90. As previously described, the forming tool 222 is engaged with the wire mesh structure 90 by moving the wire mesh structure 90, the forming tool 222, or both. The movement of the forming tool 222, the wire mesh structure 90, or both may be started before the steam 248 is ejected using the nozzle 234, after the steam 248 is ejected using the nozzle 234, or simultaneously with the start of the ejection of the steam 248 using the nozzle 234. It is also contemplated that the forming tool 222 may be engaged with the wire mesh structure 90 before the steam 248 is ejected using the nozzle 234, after the steam 248 is ejected using the nozzle 234, or simultaneously with the start of the ejection of the steam 248 using the nozzle 234.

[0124] In the illustrated configuration, the forming tool 222 is engaged with the wire mesh structure 90 by moving the forming tool 222 toward the wire mesh structure 90 using the positioning device 224. The wire mesh structure 90 and the forming tool 222 are in contact with each other. Fig. 9 246 is sectioned to better illustrate the forming tool 222 engaged with the wire mesh structure 90. The engagement of the forming tool 222 against the wire mesh structure 90 causes the forming tool 222 to exert a force on the filaments 52 that have been softened by the steam 248 and optionally heated by the forming tool 222. In response to the force, the softened filaments 52 are reshaped by the forming tool 222 and its forming features 246. For example, the softened filaments 52 are reshaped or reformed around the forming features 246, while other filaments 52 that are not engaged by the forming tool 222 or are not sufficiently heated may not be reshaped. Fig.14 and Fig.15 An example of a remodeling wire 52 is best shown.

[0125] exist Fig.14 , an enlarged view of a portion of a wire mesh structure 90 is shown. A plurality of wires 52 are shown in an initial configuration prior to being reshaped or reshaped. The initial configuration may be the configuration provided when the wire mesh structure 90 is initially manufactured. For purposes of illustration, a location on one wire 52 is designated as point A, and a location on another wire 52 is designated as point B. Point A and Fig.14 Point B in is spaced apart from and does not touch point B.

[0126] exist Fig.15, an enlarged view of a portion of the wire mesh structure 90 after being reshaped or reshaped using forming tools 222, 222', and / or 222" is shown. The wire 52 including point A has been reshaped by forming tools 222, 222', and / or 222" so that the wire 52 including point A moves downward from the perspective shown and moves into contact with the wire 52 including point B. Although the wire 52 including point A has been reshaped and moved into contact with the wire 52 including point B, no new bonds are created between the wires.

[0127] Reference again Fig. 9 , forming tool 222 engages or applies force against wire mesh structure 90 for a sufficient period of time to allow wire 52 to be reformed or reshaped. As an example, forming tool 222 may engage wire mesh structure 90 for approximately 1 to 10 seconds, but it is contemplated that if wire 52 is sufficiently heated prior to engagement, the time period may be less than 1 second, and the time period may be greater than 10 seconds, such as when wire 52 is not heated prior to engagement.

[0128] refer to Fig.10 , the forming tool 222 is reset. By operating the positioning device 224 to retract the forming tool 222 to Figure 7 The forming tool 222 is reset to the position shown. The flow of steam 248 through the nozzle 234 can be terminated before retracting the forming tool 222, after starting to retract the forming tool 222, or simultaneously with starting to retract the forming tool 222. The flow of steam 248 is terminated by closing the nozzle valve 236, the control valve 254, or both. Cutting off the flow of steam 248 before raising the forming tool 222 can reduce energy consumption and can help avoid continued heating of the wire 52 and potential excessive softening or melting of the wire 52.

[0129] and Fig.11 and Fig.12 The method steps associated with the configuration shown in Figure 7-10 . For example, forming tool 222' may start in a retracted position with one or more valves (such as control valve 254 and / or nozzle valve 236) closed so that steam 248 is not ejected by nozzle 234. One or more valves are opened so that steam 248 is ejected by nozzle 234. Steam 248 is directed toward the position on the wire mesh structure 90 where forming tool 222' will engage wire mesh structure 90. Optionally, some steam 248 may be directed toward forming tool 222' to heat forming tool 222'. As previously described, steam 248 heats wire 52 and inhibits wire 52 from bonding to forming tool 222'.

[0130] By moving forming tool 222', wire mesh structure 90 or both, forming tool 222' is engaged with wire mesh structure 90. The engagement of forming tool 222 against wire mesh structure 90 causes forming tool 222 to apply force against the wire 52 softened by steam 248 and optionally heated forming tool 222. As a result, softened wire 52 is reshaped by forming tool 222'. For example, softened wire 52 can be reshaped or reorganized around forming feature 246', while other wires 52 or reshaped wires 52 not engaged by forming tool 222' are not reshaped. Forming tool 222' can engage wire mesh structure 90 within a sufficient period of time to allow wire 52 to be reorganized or reshaped as described above. Finally, forming tool 222' can be reset by operating positioning device 224 and terminating the flow rate of steam 248 flowing through nozzle 234.

[0131] Fig.11 and Fig.12 The forming tool 222' depicted in FIG. 1 has a circular cross-section; however, it should be understood that the forming tool 222' can have a non-circular cross-section or a combination of circular and non-circular cross-sections. For example, a forming tool 222' having a V-shaped cross-section can form a V-shaped channel 174, such as Figure 5G Similarly, Fig.11 and Fig.12 The forming tool 222' in FIG. 2 is depicted as having a straight or linear configuration; however, it is contemplated that the forming tool 222' may have a curved or non-linear configuration, or a combination of straight and curved or linear and non-linear segments.

[0132] Methods associated with forming system 200 according to some embodiments involve forming a wire mesh structure, such as wire mesh structure 90. In various examples, the method may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0133] The method includes spraying steam (e.g., steam 248) onto a wire mesh structure (e.g., wire mesh structure 90), the wire mesh structure (e.g., wire mesh structure 90) including filaments (e.g., filaments 52) of a thermoplastic material, the filaments (e.g., filaments 52) being randomly looped and bonded, wherein the spraying steam (e.g., steam 248) heats at least some of the filaments (e.g., filaments 52).

[0134] The method includes engaging a forming tool (e.g., forming tool 222 and / or 222') with a wire (e.g., wire 52) that has been heated by steam (e.g., steam 248), wherein engaging the forming tool (e.g., forming tool 222 and / or 222') reshapes the wire mesh structure (e.g., wire mesh structure 90).

[0135] In some embodiments, the filament (eg, filament 52 ) is heated by steam (eg, steam 248 ) to a temperature below the melting temperature of the thermoplastic material.

[0136] In some embodiments, steam (eg, steam 248 ) is sprayed onto a mesh structure (eg, mesh structure 90 ) prior to engaging a forming tool (eg, forming tools 222 and / or 222 ′) with a wire (eg, wire 52 ).

[0137] In some embodiments, when steam (eg, steam 248 ) is ejected onto a wire mesh structure (eg, wire mesh structure 90 ), a liquid coating accumulates on the wires (eg, wires 52 ).

[0138] In some embodiments, a forming tool (eg, forming tool 222 and / or 222') contacts the liquid coating.

[0139] In some embodiments, the forming tool (eg, forming tool 222 and / or 222') is heated before the forming tool (eg, forming tool 222 and / or 222') engages the filament (eg, filament 52).

[0140] In some embodiments, steam (eg, steam 248 ) heats a forming tool (eg, forming tools 222 and / or 222 ′) while the forming tool engages the wire (eg, wire 52 ).

[0141] In some embodiments, injecting steam (e.g., steam 248) includes injecting steam (e.g., steam 248) using a first nozzle (e.g., nozzle 234) and a second nozzle (e.g., nozzle 234), a first nozzle valve (e.g., nozzle valve 236) controls a flow rate of steam (e.g., steam 248) flowing to the first nozzle (e.g., nozzle 234), a second nozzle valve (e.g., nozzle valve 236) controls a flow rate of steam (e.g., steam 248) flowing to the second nozzle (e.g., nozzle 234), and an amount of steam (e.g., steam 248) provided to the first nozzle (e.g., nozzle 234) using the first nozzle valve (e.g., nozzle 236) is different from an amount of steam (e.g., steam 248) provided to the second nozzle (e.g., nozzle 234) using the second nozzle valve (e.g., nozzle 236).

[0142] In some embodiments, after reshaping the mesh structure (eg, mesh structure 90 ), terminating the injection of steam (eg, steam 248 ) and disengaging the forming tool (eg, forming tool 222 and / or 222 ′) from the mesh structure (eg, mesh structure 90 ) occurs.

[0143] In some embodiments, steam (e.g., steam 248) heats a forming tool (e.g., forming tool 222 and / or 222') before the forming tool (e.g., forming tool 222 and / or 222') engages a wire (e.g., wire 52), and heats a forming tool (e.g., forming tool 222 and / or 222') while the forming tool (e.g., forming tool 222 and / or 222') engages a wire (e.g., wire 52).

[0144] In some embodiments, injecting steam (e.g., steam 248) includes injecting steam (e.g., steam 248) using a forming tool (e.g., forming tool 222 and / or 222'), the forming tool (e.g., forming tool 222 and / or 222') including one or more nozzles (e.g., nozzle 234) fluidly connected to a manifold (e.g., 242 and / or 242') and a tool body (e.g., tool body 230 and / or 230') fixedly positioned relative to the plurality of nozzles (e.g., nozzle 234).

[0145] In some embodiments, the plurality of nozzles (eg, nozzles 234 ) do not contact the wire (eg, wire 52 ) when injecting steam (eg, steam 248 ).

[0146] In some embodiments, engaging a forming tool (e.g., forming tool 222 and / or 222') with a wire (e.g., wire 52) includes actuating a tool body (e.g., tool body 230 and / or 230') at least partially into a wire mesh structure (e.g., wire mesh structure 90) to apply pressure that reshapes the wire mesh structure (e.g., wire mesh structure 90).

[0147] In some embodiments, a plurality of nozzles (eg, nozzles 234 ) are spaced apart from a wire mesh structure (eg, wire mesh structure 90 ) when a tool body (eg, tool body 230 ′) is at least partially actuated into the wire mesh structure (eg, wire mesh structure 90 ).

[0148] refer to Fig.13, in order to reshape the wire 52, force is applied by steam 248, rather than by the engagement of the forming tool 222'' with the wire 52. The method steps associated with this configuration are similar to those discussed previously. First, the wire mesh structure 90 and the forming tool 222'' are aligned so that the forming tool 222'' is positioned to reshape the wire mesh structure 90 in one or more predetermined configurations. Steam 248 is then sprayed through one or more nozzles 234. Steam 248 can be sprayed by the nozzle 234 by opening the control valve 254 and one or more nozzle valves 236 (if any). Steam 248 is directed toward one or more wires 52 of the wire mesh structure 90 to heat the wire 52 by a sufficient amount or within a sufficient period of time so that the wire 52 can be reshaped or reshaped. The wire 52 is reshaped by the pressure applied by steam 248 rather than by contacting, engaging or directly applying force against the wire 52 with the forming tool 222''.

[0149] The force applied by the steam 248 against one or more of the wires 52 is controlled by the control system 228, such as by controlling the position of the nozzles 234, controlling the movement of the nozzles 234, controlling the flow rate (e.g., flow rate) of the steam 248 through one or more of the nozzles 234, controlling the amount of time that the steam 248 is applied to the wires 52, controlling the number of nozzles or nozzle orifices that spray the steam 248 toward the wires, or a combination thereof. For example, the amount of force applied by the steam 248 can be increased by opening the nozzle valve 236 by a greater amount to increase the steam flow rate and the amount of force applied, by holding the nozzles 234 on the wires 52 for a longer period of time, by using steam from a greater number of nozzles 234 to apply force on the wires 52, by moving the nozzles 234 closer to the wires 52 to increase the amount of steam 248 that pushes the wires 52 (rather than spraying through the wires 52 or against another wire 52), or a combination thereof. Increasing the amount of force applied to the wires 52 can result in greater wire movement, and can form deeper or wider notches into the wire mesh structure 90.

[0150] Conversely, the amount of force applied by the steam 248 can be reduced by closing a valve, by opening the nozzle valve 236 a smaller amount to reduce the steam flow rate and the amount of force applied, by holding the nozzle 234 on the wire 52 for a shorter period of time, by using steam from a smaller number of nozzles 234 to apply force on the wire 52, by moving the nozzle 234 further away from the wire 52 to reduce the amount of steam 248 pushing the wire 52, or a combination thereof. Reducing the amount of force applied to the wire can result in reduced wire movement, and can form shallower or narrower notches into the wire mesh structure 90. The pressure applied by the steam can vary as the forming tool 222″ moves.

[0151] In some configurations, the nozzle 234 is moved by the positioning device 224″ while ejecting steam 248, so that the steam 248 heats and reshapes the additional wire 52 of the wire mesh structure 90. Thus, the travel path of the nozzle 234 can be used to create various styling features in the wire mesh structure 90 without contacting the wire mesh structure 90. When the nozzle 234 moves over an area of ​​the wire mesh structure 90 that is not being reshaped, the flow of steam 248 is interrupted or temporarily turned off.

[0152] Methods associated with forming system 200 according to some embodiments involve forming a wire mesh structure, such as wire mesh structure 90. In various examples, the method may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0153] The method includes using a forming tool (e.g., forming tool 222'') to spray steam (e.g., steam 248) onto a wire mesh structure (e.g., wire mesh structure 90), the wire mesh structure (e.g., wire mesh structure 90) including filaments (e.g., filaments 52) of randomly looped and bonded thermoplastic material, wherein the forming tool (e.g., forming tool 222'') has a nozzle (e.g., nozzle 234) that sprays steam (e.g., steam 248), the steam (e.g., steam 248) heats and applies pressure to at least some of the filaments (e.g., filaments 52) to reshape the wire mesh structure (e.g., wire mesh structure 90), and the forming tool (e.g., forming tool 222'') does not engage the wire mesh structure (e.g., wire mesh structure 90).

[0154] In some embodiments, reshaping the wire mesh structure (eg, wire mesh structure 90 ) includes moving a nozzle (eg, nozzle 234 ) relative to the wire mesh structure (eg, wire mesh structure 90 ) while injecting steam (eg, steam 248 ).

[0155] In some embodiments, moving a nozzle (eg, nozzle 234 ) while injecting steam (eg, steam 248 ) heats and reshapes additional wires (eg, wire 52 ) of a wire mesh structure (eg, wire mesh structure 90 ).

[0156] In some embodiments, steam (eg, steam 248 ) is sprayed directly onto a mesh structure (eg, mesh structure 90 ).

[0157] In some embodiments, the pressure applied by the steam (eg, steam 248 ) varies as a forming tool (eg, forming tool 222 ″) moves.

[0158] In some embodiments, a forming tool (eg, forming tool 222 ″) is disposed on a positioning device (eg, positioning device 224 ″).

[0159] For example, using steam to heat the wire allows the wire mesh structure 90 to be reshaped after its initial manufacture. In this way, the wire mesh structure 90 can be reshaped from an initial configuration to another configuration that is more suitable for a seating application and can improve seat occupant comfort. Reshaping is achieved without cutting or removing material from the wire mesh structure 90, which reduces or eliminates material removal operations and reduces waste. Reshaping can be accomplished using steam rather than by using chemicals or softeners. In addition, steam can prevent the wire from adhering to the forming tool without the use of oil or other traditional lubricants, which can help reduce costs and allow the wire mesh structure to be quickly reshaped into a desired shape.

[0160] refer to Figure 17-Figure 23 , another example of a cushion (e.g., cushion 50) is shown. In this example, the wire mesh structure 90 of the cushion is folded to create a desired shape. The folding can be facilitated by forming recesses or grooves in the wire mesh structure 90 using the previously described cutting system 100 or forming system 200. Figure 17-Figure 22 Grouped in pairs, where even-numbered figures are top views and odd-numbered figures are side views.

[0161] refer to Fig.17 and Fig.18 , a sheet or block of a wire mesh structure 90 such as may be produced using the manufacturing system 60 is shown. For simplicity, the wire mesh structure 90 is shown as having a generally rectangular shape and a rectangular cross-section. The wire mesh structure 90 has a plurality of sides, including a first side 400, a second side 402, a third side 404, and a fourth side 406. In this example, the first side 400 is disposed opposite the second side 402, and the third side 404 is disposed opposite the fourth side 406. The third side 404 may be a front side, and the fourth side 406 may be a rear side. The wire mesh structure 90 may also include a first lateral side 408 and a second lateral side 410 disposed opposite the first lateral side 408.

[0162] refer to Fig.19 and Fig. 20 , shows a block of a wire mesh structure 90 after being formed to provide different shapes. The wire mesh structure 90 can be formed by removing material using a cutting system 100, by forming or reshaping the wires of the wire mesh structure 90 using a forming system 200, or both. It is also contemplated that the wire mesh structure 90 can be molded in a mold to form or reshape the wires.

[0163] exist Fig.19 In FIG. 1 , when viewed from above, the perimeter of the wire mesh structure 90 is shown as having a curved or contoured shape, such as by Fig.17 and Fig.18 and Fig.19 and Fig. 20The curved or contoured configuration may include shaping or removing material from one or more sides of the wire mesh structure 90. Fig.19 and Fig. 20 , the wire mesh structure 90 is shown to have a plurality of grooves, such as a first groove 420, a second groove 422, a third groove 424, and a fourth groove 426. The grooves may have a linear configuration or a non-linear configuration.

[0164] The first trench 420 and the second trench 422 are shown as being formed in the first side 400 and extending partially toward the second side 402. The first trench 420 and the second trench 422 are depicted as extending from the third side 404 to the fourth side 406.

[0165] The portion of the wire mesh structure 90 disposed between the bottom of the first groove 420 and the second side 402 is referred to as a first foldable connecting segment 430. The first foldable connecting segment 430 includes a wire 52 that connects a first portion 440 of the wire mesh structure 90 to a second portion 442 of the wire mesh structure 90, the second portion 442 being disposed on a side of the first groove 420 opposite to the first portion 440. In the illustrated configuration, the first portion 440 is a central portion or a central seating portion of the wire mesh structure 90. The first foldable connecting segment 430 may have a linear configuration, a non-linear configuration, or a combination thereof. In the illustrated configuration, the first foldable connecting segment 430 is linear.

[0166] The portion of the wire mesh structure 90 disposed between the bottom of the second groove 422 and the second side 402 is referred to as a second foldable connecting segment 432. The second foldable connecting segment 432 includes a wire 52 that connects the first portion 440 of the wire mesh structure 90 to a third portion 444 of the wire mesh structure 90, which is disposed on a side of the second groove 422 opposite to the first portion 440. The second foldable connecting segment 432 can have a linear configuration, a non-linear configuration, or a combination thereof. In the configuration shown, the second foldable connecting segment 432 is linear.

[0167] The first groove 420 and the second groove 422 can have any suitable cross-sectional shape. In the illustrated configuration, the first groove 420 and the second groove 422 are shown as having a generally V-shaped or slit-like configuration.

[0168] Main references Fig.19 , the third groove 424 and the fourth groove 426 (if any) are depicted as being formed in the second side 402 and extending partially through the wire mesh structure 90 toward the first side 400. Optionally, the third groove 424 and the fourth groove 426 may extend to the first foldable connecting segment 430, the second foldable connecting segment 432, or both.

[0169] It should be understood that when the wire mesh structure is formed, the wire mesh structure 90 can be Fig.19 and Fig. 20 The illustrated position is inverted or flipped. For example, the wire mesh structure 90 can be positioned with the first side 400 facing upward to facilitate access by the cutting system 100, the forming system 200, or both.

[0170] refer to Fig.21 and Fig. 22 , shows the wire mesh structure 90 after the wire mesh structure 90 is folded along the first foldable connecting section 430 and the second foldable connecting section 432 .

[0171] In some configurations, folding the second portion 442 along the first foldable connecting segment 430 positions the second portion 442 on the first portion 440. Folding the second portion 442 on the first portion 440 can position the second portion 442 in contact with the first portion 440. For example, folding the second portion 442 along the first foldable connecting segment 430 rotates the second portion 442 relative to the first portion 440 so that the portion of the second side 402 where the second portion 442 is disposed is folded and can be folded into contact with the portion of the second side 402 where the first portion 440 is disposed. Folding the second portion 442 in this manner can produce a seat cushion (e.g., cushion 32 and / or 42) in which the second portion 442 forms a first side bolster.

[0172] In some configurations, folding the third portion 444 along the second foldable connecting segment 432 positions the third portion 444 on the first portion 440. Folding the third portion 444 on the first portion 440 can position the third portion 444 in contact with the first portion 440. For example, folding the third portion 444 along the second foldable connecting segment 432 rotates the third portion 444 relative to the first portion 440 so that the portion of the second side 402 where the third portion 444 is disposed is folded and can be folded into contact with the portion of the second side 402 where the first portion 440 is disposed. Folding the third portion 444 in this manner can produce a seat cushion (e.g., cushion 32 and / or 42) in which the third portion 444 forms a second side bolster.

[0173] Although the first portion 440 and the second portion 442 are shown as being rotated in an upward direction, this is not intended to be limiting, as the foldable segment can be rotated in any suitable direction based on the position of the groove and the associated foldable connecting segment. In addition, in some configurations, the foldable segment can be folded over a smaller angular distance. For example, the foldable segment can be folded so that the opposing sides of the V-shaped slit move into engagement with each other.

[0174] refer to Fig.23, the folded portion is fixed. For example, after folding the second portion 442, the second portion 442 is fixed to the first portion 440, thereby maintaining the second portion 442 in its folded position. Similarly, after folding the third portion 444, the third portion 444 is fixed to the first portion 440, thereby maintaining the third portion 444 in its folded position. The fixing of the folded portion is performed by Fig.23 440. The folded portion, such as the second portion 442 or the third portion 444, may be secured in any suitable manner. For example, the attachment mark 450 may indicate attachment with a mechanical fastener (such as a clip, a ring, a hook and loop fastener, a clamp, or the like), with a chemical or adhesive bond, or by directly bonding one or more wires 52 of the folded portion to the first portion 440, such as by heat riveting or melting one or more wires 52 so that new bonding points are formed on the wires 52. It is also contemplated that the folded portion may not be secured.

[0175] It should be understood that grooves or foldable connecting sections can be provided on opposite sides of the wire mesh structure 90 to allow the wire mesh structure 90 to fold in different directions. Therefore, different portions of the pad can be folded in different planes, along different axes or along different sides of the wire mesh structure 90.

[0176] It should also be understood that a liner (e.g., liner 50) may be provided by stacking multiple layers of wire mesh structure 90, and one or more layers may not be provided with a foldable connecting section. For example, a foldable connecting section may be provided in the top wire mesh structure layer, but not in other layers provided below or behind the top wire mesh structure layer. It should also be understood that layers may be stacked laterally rather than vertically.

[0177] The pad (e.g., pad 32 and / or 42) includes a wire mesh structure (e.g., wire mesh structure 90) including wires (e.g., wires 52) of a thermoplastic material, the wires (e.g., wires 52) being randomly looped and bonded, wherein the wire mesh structure (e.g., wire mesh structure 90) has grooves (e.g., grooves 168 and / or 420 and / or 422) extending from a first side (e.g., first side 400) of the wire mesh structure (e.g., wire mesh structure 90) toward a second side (e.g., second side 402) of the wire mesh structure (e.g., wire mesh structure 90). 2) disposed opposite to a first side surface (e.g., first side surface 400), a groove (e.g., groove 168 and / or 420 and / or 422) and a second side surface (e.g., second side surface 402) cooperate to define a foldable connecting segment (e.g., foldable connecting segment 430) therebetween, wherein the foldable connecting segment (e.g., foldable connecting segment 430) connects a first portion (e.g., first portion 440) of a wire mesh structure (e.g., wire mesh structure 90) to a second portion (e.g., second portion 442) of the wire mesh structure (e.g., wire mesh structure 90), and the second portion (e.g., second portion 442) is folded over the first portion (e.g., first portion 440).

[0178] In some embodiments, a second side (eg, second side 402 ) of a first portion (eg, first portion 440 ) contacts a second side (eg, second side 402 ) of a second portion (eg, second portion 442 ).

[0179] In some embodiments, a first portion (eg, first portion 440 ) is secured to a second portion (eg, second portion 442 ).

[0180] In some embodiments, the cushion (eg, cushion 32 and / or 42 ) is a seat cushion.

[0181] In some embodiments, the second portion (eg, second portion 442 ) is a side pad of a cushion (eg, cushions 32 and / or 42 ).

[0182] In some embodiments, a first portion (eg, first portion 440 ) at least partially defines a central seating portion of a cushion (eg, cushions 32 and / or 42 ).

[0183] Methods according to some embodiments involve manufacturing a pad (eg, pads 32 and / or 42). In various examples, the method may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0184] The method includes forming grooves (e.g., grooves 168 and / or 420 and / or 422) in a wire mesh structure (e.g., wire mesh structure 90), the grooves (e.g., grooves 168 and / or 420 and / or 422) extending from a first side (e.g., first side 400) of the wire mesh structure (e.g., wire mesh structure 90) toward a second side (e.g., second side 402) of the wire mesh structure (e.g., wire mesh structure 90) that is different from the first side (e.g., first side 400), the grooves (e.g., grooves 168 and / or 420 and / or 422) and the second side (e.g., second side 402) cooperating to define a foldable connecting segment (e.g., foldable connecting segment 430) therebetween, and folding the wire mesh structure (e.g., wire mesh structure 90) along the foldable connecting segment (e.g., foldable connecting segment 430) therebetween.

[0185] In some embodiments, the foldable connecting segment (eg, foldable connecting segment 430 ) is linear.

[0186] In some embodiments, the foldable connecting segment (e.g., foldable connecting segment 430) extends from a third side (e.g., third side 404) of the wire mesh structure (e.g., wire mesh structure 90) to a fourth side (e.g., fourth side 406) of the wire mesh structure (e.g., wire mesh structure 90) that is different from the third side (e.g., third side 404).

[0187] In some embodiments, the third side extends from the first side (eg, first side 400 ) to the second side (eg, second side 402 ).

[0188] In some embodiments, the fourth side (eg, fourth side 406 ) extends from the first side (eg, first side 400 ) to the second side (eg, second side 402 ).

[0189] In some embodiments, a first side (eg, first side 400 ) is disposed opposite to a second side (eg, second side 402 ), and a third side (eg, third side 404 ) is disposed opposite to a fourth side (eg, fourth side 406 ).

[0190] In some embodiments, a foldable connecting segment (e.g., foldable connecting segment 430) connects a first portion (e.g., first portion 440) of a mesh structure (e.g., mesh structure 90) with a second portion (e.g., second portion 442) of the mesh structure (e.g., mesh structure 90), and folding the mesh structure (e.g., mesh structure 90) along the foldable connecting segment (e.g., foldable connecting segment 430) includes folding the second portion (e.g., second portion 442) over the first portion (e.g., first portion 440).

[0191] In some embodiments, folding the second portion (eg, second portion 442 ) over the first portion (eg, first portion 440 ) includes folding the second portion (eg, second portion 442 ) into contact with the first portion (eg, first portion 440 ).

[0192] In some embodiments, after folding the second portion (eg, second portion 442 ), the second portion (eg, second portion 442 ) is secured to the first portion (eg, first portion 440 ) to maintain the second portion (eg, second portion 442 ) in the folded position.

[0193] In some embodiments, securing the second portion (eg, second portion 442 ) to the first portion (eg, first portion 440 ) includes bonding the first portion (eg, first portion 440 ) to the second portion (eg, second portion 442 ).

[0194] In some embodiments, securing the second portion (eg, second portion 442) to the first portion (eg, first portion 440) includes attaching the first portion (eg, first portion 440) to the second portion (eg, second portion 442) using a fastener.

[0195] In some embodiments, forming grooves (eg, grooves 420 and / or 422 ) in a wire mesh structure (eg, wire mesh structure 90 ) includes cutting the wire mesh structure (eg, wire mesh structure 90 ).

[0196] Clause 1. A method comprising cutting a wire mesh structure via a fluid jet.

[0197] Clause 2. The method of clause 1, wherein cutting the wire mesh structure with the fluid jet at least partially forms a cushion.

[0198] Clause 3. The method of Clause 2, further comprising attaching the cushion to a frame of a seat assembly.

[0199] Clause 4. The method of Clause 3, further comprising: positioning a trim cover over the cushion; and attaching the trim cover to the cushion, to the frame, or to the cushion and the frame.

[0200] Clause 5. The method according to any one of clauses 1 to 4, further comprising forming the mesh structure using filaments of thermoplastic material, the filaments being randomly looped and bonded.

[0201] Clause 6. The method of Clause 5, wherein forming the wire mesh structure comprises extruding the thermoplastic material through a die to form filaments, and then passing the filaments through a funnel.

[0202] Clause 7. The method of Clause 6, further comprising cutting the wire mesh structure after the wire passes through the funnel.

[0203] Clause 8. The method of any one of clauses 1 to 7, further comprising controlling a travel speed of a cutting head to control the depth of the cut into the wire mesh structure.

[0204] Clause 9. The method of clause 8, further comprising reducing the travel speed of the cutting head to increase the depth of the cut.

[0205] Clause 10. The method of any one of clauses 8 to 9, further comprising moving the cutting head closer to the wire mesh structure to increase the depth of the cut.

[0206] Clause 11. The method of any one of clauses 8 to 10, further comprising increasing a pressure of a fluid provided to the cutting head to increase the depth of the cutting.

[0207] Clause 12. The method of any one of clauses 8 to 11, further comprising increasing a fluid flow rate of the fluid jet to increase the depth of the cut.

[0208] Clause 13. The method of any of Clauses 8 to 13, wherein cutting the wire mesh structure using the fluid jet comprises positioning the cutting head away from the wire mesh structure such that the cutting head does not contact the wire mesh structure.

[0209] Clause 14. The method of any one of clauses 8 to 13, further comprising controlling an automated mechanism supporting the cutting head to move the cutting head along a cutting path relative to the wire mesh structure.

[0210] Clause 15. The method of clause 14, further comprising controlling the automated mechanism in at least one degree of freedom to move the cutting head along the cutting path.

[0211] Clause 16. The method of clause 14, further comprising controlling the automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

[0212] Clause 17. The method of any one of Clauses 1 to 16, further comprising cutting completely through the wire mesh structure via the fluid jet.

[0213] Clause 18. The method according to clauses 1 to 17, further comprising partially cutting through the wire mesh structure via the fluid jet.

[0214] Clause 19. The method of any one of Clauses 1 to 18, further comprising cutting one or more of a planar surface and a curved feature in the wire mesh structure via the fluid jet.

[0215] Clause 20. The method of any one of Clauses 1 to 19, further comprising cutting one or more of orthogonal surfaces, fillets, chamfers, and grooves in the wire mesh structure via the fluid jet.

[0216] Item 21. A method of forming a wire mesh structure, the method comprising: spraying steam onto the wire mesh structure, the wire mesh structure comprising filaments of thermoplastic material, the filaments being randomly looped and bonded, wherein the sprayed steam heats at least some of the filaments; and engaging a forming tool with the filaments that have been heated by the steam, wherein engaging the forming tool reshapes the wire mesh structure.

[0217] Clause 22. The method of Clause 21, wherein the filaments are heated by the steam to a temperature below the melting temperature of the thermoplastic material.

[0218] Clause 23. The method of Clause 21 or Clause 22, wherein steam is sprayed onto the wire mesh structure prior to engaging the forming tool with the wire.

[0219] Clause 24. The method according to any one of clauses 21 to 23, wherein a liquid coating accumulates on the wires when steam is sprayed onto the wire mesh structure.

[0220] Clause 25. The method of any one of Clause 24, wherein the forming tool contacts the liquid coating.

[0221] Clause 26. The method of any one of Clauses 21 to 25, wherein the forming tool is heated before the forming tool engages the filament.

[0222] Clause 27. The method of any one of Clauses 21 to 26, wherein the steam heats the forming tool as the forming tool engages the filament.

[0223] Clause 28. A method according to any one of clauses 21 to 27, wherein injecting steam includes injecting steam using a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam provided to the first nozzle using the first nozzle valve is different from an amount of steam provided to the second nozzle using the second nozzle valve.

[0224] Clause 29. The method of any one of Clauses 21 to 28, further comprising terminating the injection of steam and decoupling the forming tool from the wire mesh structure after reshaping the wire mesh structure.

[0225] Clause 30. The method of any one of Clauses 21 to 29, wherein steam heats the forming tool before the forming tool engages the wire and heats the forming tool while the forming tool engages the wire.

[0226] Clause 31. The method of any one of Clauses 21 to 30, wherein injecting steam comprises injecting steam using the forming tool, the forming tool comprising a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0227] Clause 32. The method of Clause 31, wherein the plurality of nozzles do not contact the filament when ejecting steam.

[0228] Clause 33. The method of clause 31 or clause 32, wherein engaging the forming tool with the wire comprises actuating the tool body at least partially into the wire mesh structure to apply pressure that reshapes the wire mesh structure.

[0229] Clause 34. The method of any one of clauses 31 to 33, wherein the plurality of nozzles are spaced apart from the wire mesh structure when the tool body is actuated at least partially into the wire mesh structure.

[0230] Item 35. A method of forming a wire mesh structure, the method comprising: using a forming tool to spray steam onto the wire mesh structure, the wire mesh structure comprising randomly looped and bonded filaments of thermoplastic material, wherein the forming tool has a nozzle for spraying steam, the steam heats at least some of the filaments and applies pressure to at least some of the filaments, which reshapes the wire mesh structure, and the forming tool does not engage the wire mesh structure.

[0231] Clause 36. The method of Clause 35, wherein reshaping the wire mesh structure comprises moving the nozzle relative to the wire mesh structure while injecting steam.

[0232] Clause 37. The method of clause 36, wherein the nozzle is moved while spraying steam to heat and reshape the additional wires of the wire mesh structure.

[0233] Clause 38. The method according to any one of clauses 35 to 37, wherein steam is injected directly onto the wire mesh structure.

[0234] Clause 39. The method of any one of clauses 35 to 38, wherein the pressure applied by the steam varies as the forming tool moves.

[0235] Clause 40. The method according to any one of clauses 35 to 39, wherein the forming tool is arranged on a positioning device.

[0236] Clause 41. The method according to any one of clauses 1 to 20 further comprises: spraying steam onto the wire mesh structure, the wire mesh structure comprising filaments of thermoplastic material, the filaments being randomly looped and combined, wherein the sprayed steam heats at least some of the filaments; and engaging a forming tool with the filaments that have been heated by the steam, wherein engaging the forming tool reshapes the wire mesh structure.

[0237] Clause 42. The method of Clause 41, wherein the filaments are heated by the steam to a temperature below the melting temperature of the thermoplastic material.

[0238] Clause 43. The method of Clause 41 or Clause 42, wherein steam is sprayed onto the wire mesh structure prior to engaging the forming tool with the wire.

[0239] Clause 44. The method according to any one of Clauses 41 to 43, wherein a liquid coating accumulates on the wires when steam is injected onto the wire mesh structure.

[0240] Clause 45. The method of clause 44, wherein the forming tool contacts the liquid coating.

[0241] Clause 46. The method of any one of Clauses 41 to 45, wherein the forming tool is heated before the forming tool engages the filament.

[0242] Clause 47. The method of any one of Clauses 41 to 46, wherein the steam heats the forming tool as the forming tool engages the filament.

[0243] Clause 48. A method according to any one of clauses 41 to 47, wherein injecting steam includes injecting steam using a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam provided to the first nozzle using the first nozzle valve is different from an amount of steam provided to the second nozzle using the second nozzle valve.

[0244] Clause 49. The method of any one of Clauses 41 to 48, further comprising terminating the injection of steam and disengaging the forming tool from the wire mesh structure after reshaping the wire mesh structure.

[0245] Clause 50. The method of any one of Clauses 41 to 49, wherein the steam heats the forming tool before the forming tool engages the wire and heats the forming tool while the forming tool engages the wire.

[0246] Clause 51. The method of any one of clauses 41 to 50, wherein injecting steam comprises injecting steam using the forming tool, the forming tool comprising a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0247] Clause 52. The method of Clause 51, wherein the plurality of nozzles do not contact the filament when ejecting steam.

[0248] Clause 53. The method of clause 51 or clause 52, wherein engaging the forming tool with the wire comprises actuating the tool body at least partially into the wire mesh structure to apply pressure that reshapes the wire mesh structure.

[0249] Clause 54. The method of any one of clauses 51 to 53, wherein the plurality of nozzles are spaced apart from the wire mesh structure when the tool body is actuated at least partially into the wire mesh structure.

[0250] Clause 55. The method according to any one of clauses 1 to 20 further comprises: using a forming tool to spray steam onto the wire mesh structure, the wire mesh structure comprising randomly looped and bonded wires of thermoplastic material, wherein the forming tool has a nozzle for spraying steam, the steam heats at least some of the wires and applies pressure to at least some of the wires, which reshapes the wire mesh structure, and the forming tool does not engage the wire mesh structure.

[0251] Clause 56. The method of Clause 55, wherein reshaping the wire mesh structure comprises moving the nozzle relative to the wire mesh structure while injecting steam.

[0252] Clause 57. The method of clause 56, wherein moving the nozzle while injecting steam heats and reshapes the additional wires of the wire mesh structure.

[0253] Clause 58. The method according to any one of Clauses 55 to 57, wherein steam is injected directly onto the wire mesh structure.

[0254] Clause 59. The method of any one of clauses 55 to 58, wherein the pressure applied by the steam varies as the forming tool moves.

[0255] Clause 60. The method according to any one of clauses 55 to 59, wherein the forming tool is arranged on a positioning device.

[0256] Item 61. A method of manufacturing a pad, comprising: forming a groove in a wire mesh structure, the groove extending from a first side of the wire mesh structure toward a second side of the wire mesh structure different from the first side, the groove and the second side cooperating to define a foldable connecting segment therebetween; and folding the wire mesh structure along the foldable connecting segment.

[0257] Clause 62. The method of clause 61, wherein the foldable connecting segment is linear.

[0258] Clause 63. The method of clause 61 or clause 62, wherein the foldable connecting section extends from a third side of the wire mesh structure to a fourth side of the wire mesh structure that is different from the third side.

[0259] Clause 64. The method of clause 63, wherein the third side extends from the first side to the second side.

[0260] Clause 65. The method of clause 63 or clause 64, wherein the fourth side extends from the first side to the second side.

[0261] Clause 66. The method of any one of clauses 63 to 65, wherein the first side is disposed opposite the second side, and the third side is disposed opposite the fourth side.

[0262] Clause 67. A method according to any one of clauses 61 to 66, wherein the foldable connecting segment connects a first portion of the wire mesh structure to a second portion of the wire mesh structure, and folding the wire mesh structure along the foldable connecting segment includes folding the second portion over the first portion.

[0263] Clause 68. The method of Clause 67, wherein folding the second portion over the first portion comprises folding the second portion into contact with the first portion.

[0264] Clause 69. The method of Clause 67, further comprising securing the second portion to the first portion after folding the second portion, thereby maintaining the second portion in a folded position.

[0265] Clause 70. The method of Clause 69, wherein securing the second portion to the first portion comprises bonding the first portion to the second portion.

[0266] Clause 71. The method of clause 69 or clause 70, wherein securing the second portion to the first portion comprises attaching the first portion to the second portion using a fastener.

[0267] Clause 72. The method of any one of Clauses 61 to 71, wherein forming the grooves in the wire mesh structure comprises cutting the wire mesh structure.

[0268] Clause 73. The method of clause 72, wherein forming the grooves in the wire mesh structure comprises cutting the wire mesh structure using a fluid jet.

[0269] Clause 74. The method of clause 73, wherein the liner is at least partially formed by cutting the wire mesh structure using the fluid jet.

[0270] Clause 75. The method of clause 74, further comprising attaching the cushion to a frame of a seat assembly.

[0271] Clause 76. The method of Clause 75, further comprising: positioning a trim cover over the cushion; and attaching the trim cover to the cushion, to the frame, or to the cushion and the frame.

[0272] Clause 77. The method according to any one of Clauses 73 to 76, further comprising forming the mesh structure using filaments of thermoplastic material, the filaments being randomly looped and bonded.

[0273] Clause 78. The method of Clause 77, wherein forming the wire mesh structure comprises extruding the thermoplastic material through a die to form the filaments, and then passing the filaments through a funnel.

[0274] Clause 79. The method of Clause 78, further comprising cutting the wire mesh structure after the wire passes through the funnel.

[0275] Clause 80. The method of any one of Clauses 73 to 79, further comprising controlling a travel speed of a cutting head to control a depth of the cut into the wire mesh structure.

[0276] Clause 81. The method of clause 80, further comprising reducing the travel speed of the cutting head to increase the depth of the cutting.

[0277] Clause 82. The method of any one of clauses 80 to 81, further comprising moving the cutting head closer to the wire mesh structure to increase the depth of the cut.

[0278] Clause 83. The method of any one of clauses 80 to 82, further comprising increasing a pressure of a fluid provided to the cutting head to increase the depth of the cut.

[0279] Clause 84. The method of any one of clauses 80 to 83, further comprising increasing a fluid flow rate of the fluid jet to increase the depth of the cut.

[0280] Clause 85. The method of any one of Clauses 80 to 84, wherein cutting the wire mesh structure using the fluid jet comprises positioning the cutting head away from the wire mesh structure such that the cutting head does not contact the wire mesh structure.

[0281] Clause 86. The method of any one of Clauses 80 to 85, further comprising controlling an automated mechanism supporting the cutting head to move the cutting head along a cutting path relative to the wire mesh structure.

[0282] Clause 87. The method of clause 86, further comprising controlling the automated mechanism in at least one degree of freedom to move the cutting head along the cutting path.

[0283] Clause 88. The method of clause 86, further comprising controlling the automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

[0284] Clause 89. The method of any one of Clauses 73 to 88, further comprising cutting completely through the wire mesh structure via the fluid jet.

[0285] Clause 90. The method according to clauses 73 to 89, further comprising partially cutting through the wire mesh structure via a fluid jet.

[0286] Clause 91. The method of any one of Clauses 73 to 90, further comprising cutting one or more of a planar surface and a curved shape in the mesh structure via the fluid jet.

[0287] Clause 92. The method of any one of Clauses 73 to 91, further comprising cutting one or more of orthogonal surfaces, fillets, chamfers, and grooves in the wire mesh structure via the fluid jet.

[0288] Clause 93. The method of any one of Clauses 61 to 71, wherein forming the grooves in the wire mesh structure comprises reshaping wires of the wire mesh structure without cutting the wires.

[0289] Item 94. A method according to item 93, wherein forming the groove includes spraying steam onto the wire mesh structure, the wire mesh structure including filaments of thermoplastic material, the filaments being randomly looped and combined, wherein the sprayed steam heats at least some of the filaments; and engaging a forming tool with the filaments that have been heated by the steam, wherein engaging the forming tool forms the groove.

[0290] Clause 95. The method of Clause 94, wherein the filaments are heated by the steam to a temperature below the melting temperature of the thermoplastic material.

[0291] Clause 96. The method of clause 94 or clause 95, wherein steam is sprayed onto the wire mesh structure prior to engaging the forming tool with the wire.

[0292] Clause 97. The method of any one of Clauses 94 to 96, wherein a liquid coating accumulates on the wires when steam is injected onto the wire mesh structure.

[0293] Item 98. The method of Item 97, wherein the forming tool contacts the liquid coating.

[0294] Clause 99. The method of any one of clauses 94 to 98, wherein the forming tool is heated before the forming tool engages the filament.

[0295] Clause 100. The method of any one of clauses 94 to 99, wherein the steam heats the forming tool as the forming tool engages the filament.

[0296] Clause 101. A method according to any one of clauses 94 to 100, wherein injecting steam includes injecting steam using a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam provided to the first nozzle using the first nozzle valve is different from an amount of steam provided to the second nozzle using the second nozzle valve.

[0297] Clause 102. The method of any one of Clauses 94 to 101, further comprising terminating the injection of steam and disengaging the forming tool from the wire mesh structure after reshaping the wire mesh structure.

[0298] Clause 103. The method of any one of Clauses 94 to 102, wherein the steam heats the forming tool before the forming tool engages the filament and heats the forming tool while the forming tool engages the filament.

[0299] Clause 104. The method of any one of clauses 94 to 103, wherein injecting steam comprises injecting steam using the forming tool, the forming tool comprising a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0300] Clause 105. The method of clause 104, wherein the plurality of nozzles do not contact the filament when spraying steam.

[0301] Clause 106. The method of clause 104 or clause 105, wherein engaging the forming tool with the wire comprises actuating the tool body at least partially into the wire mesh structure to apply pressure that reshapes the wire mesh structure.

[0302] Clause 107. The method of any one of clauses 104 to 106, wherein the plurality of nozzles are spaced apart from the wire mesh structure when the tool body is actuated at least partially into the wire mesh structure.

[0303] Item 108. A method according to item 93, wherein forming the groove includes: using a forming tool to spray steam onto the wire mesh structure, the wire mesh structure includes randomly looped and bonded filaments of thermoplastic material, wherein the forming tool has a nozzle for spraying steam, the steam heats at least some of the filaments and applies pressure to at least some of the filaments, which reshapes the wire mesh structure to form the groove, and the forming tool does not engage the wire mesh structure.

[0304] Clause 109. The method of clause 108, wherein reshaping the wire mesh structure comprises moving a nozzle relative to the wire mesh structure while injecting steam.

[0305] Clause 110. The method of clause 109, wherein moving the nozzle while injecting steam heats and reshapes the additional wires of the wire mesh structure.

[0306] Clause 111. The method according to any one of Clauses 108 to 110, wherein steam is injected directly onto the wire mesh structure.

[0307] Clause 112. The method of any one of clauses 108 to 111, wherein the pressure exerted by the steam varies as the forming tool moves.

[0308] Clause 113. A method according to any one of clauses 108 to 112, wherein the forming tool is disposed on a positioning device.

[0309] Clause 114. A pad comprising: a wire mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and bonded, wherein the wire mesh structure has a groove extending from a first side of the wire mesh structure toward a second side of the wire mesh structure, the second side being disposed opposite to the first side, the groove and the second side cooperating to define a foldable connecting section therebetween, wherein the foldable connecting section connects a first portion of the wire mesh structure to a second portion of the wire mesh structure, and the second portion is folded over the first portion.

[0310] Clause 115. The pad of clause 114, wherein the second side of the first portion contacts the second side of the second portion.

[0311] Clause 116. A cushion according to clause 114 or clause 115, wherein the first portion is secured to the second portion.

[0312] Clause 117. The cushion of any one of clauses 114 to 116, wherein the cushion is a seat cushion.

[0313] Clause 118. The cushion of any one of clause 116, wherein the second portion is a side bolster of the seat cushion.

[0314] Clause 119. A cushion as described in clause 117 or clause 118, wherein the first portion at least partially defines a central seating portion of the cushion.

[0315] Clause 120. A pad manufactured according to the method of any one of clauses 1 to 20.

[0316] Clause 121. A pad manufactured according to the method of any one of clauses 21 to 34.

[0317] Clause 122. A pad manufactured according to the method of any one of clauses 35 to 40.

[0318] Clause 123. A pad manufactured according to the method of any one of clauses 41 to 54.

[0319] Clause 124. A pad manufactured according to the method of any one of clauses 55 to 60.

[0320] Clause 125. A pad manufactured according to the method of any one of clauses 61 to 113.

[0321] 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.

Claims

1. A method comprising: Cutting the wire mesh structure with a fluid jet.

2. The method according to claim 1, wherein: The screen structure is at least partially formed into a cushion by cutting the screen structure with the fluid jet.

3. The method of claim 2, further comprising attaching the cushion to a frame of a seat assembly.

4. The method according to claim 3, further comprising: positioning a trim cover on the cushion; and attaching the trim cover to the cushion, to the frame, or to the cushion and the frame.

5. The method according to any one of claims 1 to 4, further comprising forming the mesh structure using filaments of thermoplastic material, the filaments being randomly looped and bonded.

6. The method according to claim 5, wherein: Forming the wire mesh structure includes extruding the thermoplastic material through a die to form the filaments, and then passing the filaments through a funnel.

7. The method of claim 6, further comprising cutting the wire mesh structure after the wire passes through the funnel.

8. The method of any one of claims 1 to 7, further comprising controlling the travel speed of a cutting head to control the depth of the cut into the wire mesh structure.

9. The method of claim 8, further comprising reducing a travel speed of the cutting head to increase the depth of the cutting.

10. The method of any one of claims 8 to 9, further comprising moving the cutting head closer to the wire mesh structure to increase the depth of the cutting.

11. The method of any one of claims 8 to 10, further comprising increasing the pressure of the fluid provided to the cutting head to increase the depth of the cutting.

12. The method of any one of claims 8 to 11, further comprising increasing a fluid flow rate of the fluid jet to increase the depth of the cut.

13. The method according to any one of claims 8 to 13, wherein: Cutting the wire mesh structure using the fluid jet includes positioning the cutting head away from the wire mesh structure such that the cutting head does not contact the wire mesh structure.

14. The method of any one of claims 8 to 13, further comprising controlling an automated mechanism supporting the cutting head to move the cutting head along a cutting path relative to the wire mesh structure.

15. The method of claim 14, further comprising controlling the automated mechanism in at least one degree of freedom to move the cutting head along the cutting path.

16. The method of claim 14, further comprising controlling the automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

17. The method of any one of claims 1 to 16, further comprising cutting completely through the wire mesh structure via the fluid jet.

18. The method of claims 1 to 17, further comprising partially cutting through the wire mesh structure via the fluid jet.

19. The method of any one of claims 1 to 18, further comprising cutting one or more of a planar surface and a curved feature in the wire mesh structure via the fluid jet.

20. The method of any one of claims 1 to 19, further comprising cutting one or more of orthogonal surfaces, fillets, chamfers, and grooves in the wire mesh structure via the fluid jet.

21. A method of forming a wire mesh structure, the method comprising: injecting steam onto the wire mesh structure, the wire mesh structure comprising filaments of thermoplastic material, the filaments being randomly looped and bonded, wherein the injected steam heats at least some of the filaments; as well as A forming tool is engaged with the wire that has been heated by the steam, wherein engaging the forming tool reshapes the wire mesh structure.

22. The method according to claim 21, wherein: The filaments are heated by the steam to a temperature below the melting temperature of the thermoplastic material.

23. The method of claim 21 or claim 22, wherein: Steam is sprayed onto the wire mesh structure prior to engaging the forming tool with the wire.

24. The method according to any one of claims 21 to 23, wherein: When steam is sprayed onto the wire mesh structure, a liquid coating accumulates on the wires.

25. The method according to any one of claims 24, wherein: The forming tool contacts the liquid coating.

26. The method according to any one of claims 21 to 25, wherein: The forming tool is heated before the forming tool engages the filament.

27. The method according to any one of claims 21 to 26, wherein: The steam heats the forming tool as the forming tool engages the filament.

28. The method according to any one of claims 21 to 27, wherein: Injecting steam includes injecting steam using a first nozzle and a second nozzle, a first nozzle valve controls a flow of steam to the first nozzle, a second nozzle valve controls a flow of steam to the second nozzle, and an amount of steam provided to the first nozzle using the first nozzle valve is different from an amount of steam provided to the second nozzle using the second nozzle valve.

29. The method of any one of claims 21 to 28, further comprising terminating the injection of steam and decoupling the forming tool from the wire mesh structure after reshaping the wire mesh structure.

30. The method according to any one of claims 21 to 29, wherein: The steam heats the forming tool before the forming tool engages the wire and heats the forming tool while the forming tool engages the wire.

31. The method according to any one of claims 21 to 30, wherein: Injecting the steam includes injecting the steam using the forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

32. The method according to claim 31, wherein: The plurality of nozzles do not contact the wire when spraying steam.

33. A method according to claim 31 or claim 32, wherein: Engaging the forming tool with the wire includes actuating the tool body at least partially into the wire mesh structure to apply pressure that reshapes the wire mesh structure.

34. A method according to any one of claims 31 to 33, wherein: The plurality of nozzles are spaced apart from the wire mesh structure when the tool body is at least partially actuated into the wire mesh structure.

35. A method of forming a wire mesh structure, the method comprising: Steam is ejected onto the mesh structure comprising randomly looped and bonded filaments of thermoplastic material using a forming tool, wherein the forming tool has a nozzle for ejecting steam, the steam heats at least some of the filaments and applies pressure to at least some of the filaments, which reshapes the mesh structure, and the forming tool does not engage the mesh structure.

36. The method of claim 35, wherein: Reshaping the wire mesh structure includes moving the nozzle relative to the wire mesh structure while injecting steam.

37. The method of claim 36, wherein: Moving the nozzle while injecting steam heats and reshapes the additional wires of the wire mesh structure.

38. A method according to any one of claims 35 to 37, wherein: Steam is sprayed directly onto the wire mesh structure.

39. The method according to any one of claims 35 to 38, wherein: The pressure exerted by the steam varies as the forming tool moves.

40. The method according to any one of claims 35 to 39, wherein: The forming tool is arranged on a positioning device.

41. The method according to any one of claims 1 to 20, further comprising: injecting steam onto the wire mesh structure, the wire mesh structure comprising filaments of thermoplastic material, the filaments being randomly looped and bonded, wherein the injected steam heats at least some of the filaments; and A forming tool is engaged with the wire that has been heated by the steam, wherein engaging the forming tool reshapes the wire mesh structure.

42. The method according to claim 41, wherein: The filaments are heated by the steam to a temperature below the melting temperature of the thermoplastic material.

43. A method according to claim 41 or claim 42, wherein: Steam is sprayed onto the wire mesh structure prior to engaging the forming tool with the wire.

44. A method according to any one of claims 41 to 43, wherein: When steam is sprayed onto the wire mesh structure, a liquid coating accumulates on the wires.

45. The method of claim 44, wherein: The forming tool contacts the liquid coating.

46. ​​A method according to any one of claims 41 to 45, wherein: The forming tool is heated before the forming tool engages the filament.

47. A method according to any one of claims 41 to 46, wherein: The steam heats the forming tool as the forming tool engages the filament.

48. A method according to any one of claims 41 to 47, wherein: Injecting steam includes injecting steam using a first nozzle and a second nozzle, a first nozzle valve controls a flow of steam to the first nozzle, a second nozzle valve controls a flow of steam to the second nozzle, and an amount of steam provided to the first nozzle using the first nozzle valve is different from an amount of steam provided to the second nozzle using the second nozzle valve.

49. The method of any one of claims 41 to 48, further comprising terminating the injection of steam and disengaging the forming tool from the wire mesh structure after reshaping the wire mesh structure.

50. The method according to any one of claims 41 to 49, wherein: The steam heats the forming tool before the forming tool engages the wire and heats the forming tool while the forming tool engages the wire.

51. The method according to any one of claims 41 to 50, wherein: Injecting the steam includes injecting the steam using the forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

52. The method of claim 51, wherein: The plurality of nozzles do not contact the wire when spraying steam.

53. A method according to claim 51 or claim 52, wherein: Engaging the forming tool with the wire includes actuating the tool body at least partially into the wire mesh structure to apply pressure that reshapes the wire mesh structure.

54. The method according to any one of claims 51 to 53, wherein: The plurality of nozzles are spaced apart from the wire mesh structure when the tool body is at least partially actuated into the wire mesh structure.

55. The method according to any one of claims 1 to 20, further comprising: Steam is ejected onto the mesh structure comprising randomly looped and bonded filaments of thermoplastic material using a forming tool, wherein the forming tool has a nozzle for ejecting steam, the steam heats at least some of the filaments and applies pressure to at least some of the filaments, which reshapes the mesh structure, and the forming tool does not engage the mesh structure.

56. The method of claim 55, wherein: Reshaping the wire mesh structure includes moving the nozzle relative to the wire mesh structure while injecting steam.

57. The method of claim 56, wherein: Moving the nozzle while injecting steam heats and reshapes the additional wires of the wire mesh structure.

58. A method according to any one of claims 55 to 57, wherein: Steam is sprayed directly onto the wire mesh structure.

59. The method according to any one of claims 55 to 58, wherein: The pressure exerted by the steam varies as the forming tool moves.

60. The method according to any one of claims 55 to 59, wherein: The forming tool is arranged on a positioning device.

61. A method of making a liner, comprising: forming a groove in the wire mesh structure, the groove extending from a first side of the wire mesh structure toward a second side of the wire mesh structure different from the first side, the groove and the second side cooperating to define a foldable connecting section therebetween; and The wire mesh structure is folded along the foldable connecting section.

62. The method of claim 61, wherein: The foldable connecting section is linear.

63. The method of claim 61 or claim 62, wherein: The foldable connecting section extends from a third side of the wire mesh structure to a fourth side of the wire mesh structure that is different from the third side.

64. The method of claim 63, wherein: The third side extends from the first side to the second side.

65. The method of claim 63 or claim 64, wherein: The fourth side extends from the first side to the second side.

66. The method according to any one of claims 63 to 65, wherein: The first side surface is disposed opposite to the second side surface, and the third side surface is disposed opposite to the fourth side surface.

67. The method according to any one of claims 61 to 66, wherein: The foldable connecting section connects a first portion of the wire mesh structure with a second portion of the wire mesh structure, and folding the wire mesh structure along the foldable connecting section includes folding the second portion over the first portion.

68. The method of claim 67, wherein: Folding the second portion over the first portion includes folding the second portion into contact with the first portion.

69. The method of claim 67, further comprising securing the second portion to the first portion after folding the second portion, thereby maintaining the second portion in a folded position.

70. The method of claim 69, wherein: Securing the second portion to the first portion includes bonding the first portion to the second portion.

71. The method of claim 69 or claim 70, wherein: Securing the second portion to the first portion includes attaching the first portion to the second portion using a fastener.

72. The method of any one of claims 61 to 71, wherein: Forming the grooves in the wire mesh structure includes cutting the wire mesh structure.

73. The method of claim 72, wherein: Forming the grooves in the wire mesh structure includes cutting the wire mesh structure using a fluid jet.

74. The method of claim 73, wherein: The liner is at least partially formed by cutting the wire mesh structure using the fluid jet.

75. The method of claim 74, further comprising attaching the cushion to a frame of a seat assembly.

76. The method of claim 75, further comprising: positioning a trim cover on the cushion; and attaching the trim cover to the cushion, to the frame, or to the cushion and the frame.

77. The method of any one of claims 73 to 76, further comprising forming the mesh structure using filaments of thermoplastic material, the filaments being randomly looped and bonded.

78. The method of claim 77, wherein: Forming the wire mesh structure includes extruding the thermoplastic material through a die to form the filaments, and then passing the filaments through a funnel.

79. The method of claim 78, further comprising cutting the wire mesh structure after the wire passes through the funnel.

80. The method of any one of claims 73 to 79, further comprising controlling a speed of travel of a cutting head to control the depth of the cut into the wire mesh structure.

81. The method of claim 80, further comprising reducing a travel speed of the cutting head to increase the depth of the cutting.

82. The method of any one of claims 80 to 81 further comprising moving the cutting head closer to the wire mesh structure to increase the depth of the cutting.

83. The method of any one of claims 80 to 82, further comprising increasing the pressure of the fluid provided to the cutting head to increase the depth of the cutting.

84. The method of any one of claims 80 to 83, further comprising increasing a fluid flow rate of the fluid jet to increase the depth of the cut.

85. The method according to any one of claims 80 to 84, wherein Cutting the wire mesh structure using the fluid jet includes positioning the cutting head away from the wire mesh structure such that the cutting head does not contact the wire mesh structure.

86. The method of any one of claims 80 to 85, further comprising controlling an automated mechanism supporting the cutting head to move the cutting head along a cutting path relative to the wire mesh structure.

87. The method of claim 86, further comprising controlling the automated mechanism in at least one degree of freedom to move the cutting head along the cutting path.

88. The method of claim 86, further comprising controlling the automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

89. The method of any one of claims 73 to 88, further comprising cutting completely through the wire mesh structure via the fluid jet.

90. The method of claims 73 to 89, further comprising partially cutting through the wire mesh structure via the fluid jet.

91. The method of any one of claims 73 to 90, further comprising cutting one or more of a planar surface and a curved shape in the wire mesh structure via the fluid jet.

92. The method of any one of claims 73 to 91, further comprising cutting one or more of orthogonal surfaces, fillets, chamfers, and grooves in the wire mesh structure via the fluid jet.

93. The method according to any one of claims 61 to 71, wherein: Forming the grooves in the wire mesh structure includes reshaping wires of the wire mesh structure without cutting the wires.

94. The method of claim 93, wherein: Forming the groove comprises: injecting steam onto the wire mesh structure, the wire mesh structure comprising filaments of thermoplastic material, the filaments being randomly looped and bonded, wherein the injected steam heats at least some of the filaments; and A forming tool is engaged with the wire that has been heated by the steam, wherein engaging the forming tool forms the grooves.

95. The method of claim 94, wherein: The filaments are heated by the steam to a temperature below the melting temperature of the thermoplastic material.

96. The method of claim 94 or claim 95, wherein: Steam is sprayed onto the wire mesh structure prior to engaging the forming tool with the wire.

97. The method of any one of claims 94 to 96, wherein: When steam is sprayed onto the wire mesh structure, a liquid coating accumulates on the wires.

98. The method of claim 97, wherein: The forming tool contacts the liquid coating.

99. The method of any one of claims 94 to 98, wherein: The forming tool is heated before the forming tool engages the filament.

100. The method according to any one of claims 94 to 99, wherein: The steam heats the forming tool as the forming tool engages the filament.

101. The method according to any one of claims 94 to 100, wherein: Injecting steam includes injecting steam using a first nozzle and a second nozzle, a first nozzle valve controls a flow of steam to the first nozzle, a second nozzle valve controls a flow of steam to the second nozzle, and an amount of steam provided to the first nozzle using the first nozzle valve is different from an amount of steam provided to the second nozzle using the second nozzle valve.

102. The method of any one of claims 94 to 101 further comprising terminating the injection of steam and disengaging the forming tool from the wire mesh structure after reshaping the wire mesh structure.

103. The method according to any one of claims 94 to 102, wherein: The steam heats the forming tool before the forming tool engages the wire and heats the forming tool while the forming tool engages the wire.

104. The method of any one of claims 94 to 103, wherein: Injecting the steam includes injecting the steam using the forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

105. The method of claim 104, wherein: The plurality of nozzles do not contact the wire when spraying steam.

106. The method of claim 104 or claim 105, wherein: Engaging the forming tool with the wire includes actuating the tool body at least partially into the wire mesh structure to apply pressure that reshapes the wire mesh structure.

107. The method according to any one of claims 104 to 106, wherein: The plurality of nozzles are spaced apart from the wire mesh structure when the tool body is at least partially actuated into the wire mesh structure.

108. The method of claim 93, wherein: Forming the grooves includes: using a forming tool to spray steam onto the wire mesh structure, the wire mesh structure including randomly looped and bonded filaments of thermoplastic material, wherein the forming tool has a nozzle that sprays steam, the steam heats at least some of the filaments and applies pressure to at least some of the filaments, which reshapes the wire mesh structure to form the grooves, and the forming tool does not engage the wire mesh structure.

109. The method of claim 108, wherein: Reshaping the wire mesh structure includes moving the nozzle relative to the wire mesh structure while injecting steam.

110. The method of claim 109, wherein: Moving the nozzle while injecting steam heats and reshapes the additional wires of the wire mesh structure.

111. The method according to any one of claims 108 to 110, wherein: Steam is sprayed directly onto the wire mesh structure.

112. A method according to any one of claims 108 to 111, wherein The pressure exerted by the steam varies as the forming tool moves.

113. The method according to any one of claims 108 to 112, wherein: The forming tool is arranged on a positioning device.

114. A pad comprising: A wire mesh structure comprising filaments of thermoplastic material, the filaments being randomly looped and bonded, wherein the wire mesh structure has a groove extending from a first side of the wire mesh structure toward a second side of the wire mesh structure, the second side being disposed opposite the first side, the groove and the second side cooperating to define a foldable connecting section therebetween, wherein the foldable connecting section connects a first portion of the wire mesh structure to a second portion of the wire mesh structure, and the second portion is folded over the first portion.

115. The pad of claim 114, wherein: The second side of the first portion contacts the second side of the second portion.

116. A pad according to claim 114 or claim 115, wherein The first portion is secured to the second portion.

117. A pad according to any one of claims 114 to 116, wherein The pad is a seat pad.

118. The pad of any one of claims 116, wherein The second portion is a side bolster of the seat pad.

119. A mat according to claim 117 or claim 118, wherein The first portion at least partially defines a central seating portion of the cushion.

120. A pad manufactured according to the method of any one of claims 1 to 20.

121. A pad manufactured according to the method of any one of claims 21 to 34.

122. A pad manufactured according to the method of any one of claims 35 to 40.

123. A pad manufactured according to the method of any one of claims 41 to 54.

124. A pad manufactured according to the method of any one of claims 55 to 60.

125. A pad manufactured according to the method of any one of claims 61 to 113.

Images