Extruded plastic mesh, seat assembly, cushion and / or method of forming

Abstract

The seat support is provided with a plurality of flat layers for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of flat layers are stacked on each other, and each of the plurality of stacked layers has a varying density. A seat support is provided with one or more layers of extruded thermoplastic resin mesh for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of layers may be stacked on each other.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Application Serial No. 63 / 351,902 filed on June 14, 2022; U.S. Application Serial No. 63 / 356,555 filed on June 29, 2022; U.S. Application Serial No. 63 / 355,754 filed on June 27, 2022; U.S. Application Serial No. 63 / 355,793 filed on June 27, 2022; U.S. Application Serial No. 63 / 355,700 filed on June 27, 2022; U.S. Application Serial No. 63 / 357,056 filed on June 30, 2022; U.S. Application Serial No. 63 / 355,158 filed on June 24, 2022; and U.S. Application Serial No. PA 2023 filed on April 25, 2023 70197; the disclosures of these applications are hereby incorporated herein by reference in their entirety. Technical Field

[0003] Various embodiments are directed to a vehicle seat component, a seat cushion, a seat assembly, a method for manufacturing a seat cushion, and a method for designing a seat cushion. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] For a further understanding of the nature, objects and advantages of the present disclosure, reference should be made to the following detailed description read in conjunction with the following drawings, in which like reference numerals represent like elements, and in which:

[0006] Figure 1 is a perspective cross-sectional view of a seat assembly according to some embodiments;

[0007] Figure 2 is an exploded perspective view of multiple layers of a seat assembly according to some embodiments;

[0008] Figure 3 is a side cross-sectional view of a seat assembly according to some embodiments;

[0009] Figure 3B A method according to some embodiments is shown;

[0010] Figure 4 is a front perspective view of a seat assembly according to some embodiments;

[0011] Figure 5 yes Figure 4 A front perspective view of a cushion of a seat assembly;

[0012] Figure 6 yes Figure 5 A side view of a cushion;

[0013] Figure 7 yes Figure 5 A schematic front view of a pad;

[0014] Figure 8 yes Figure 5 a front perspective view of a portion of a cushion;

[0015] Fig. 9 is a side view of a portion of a cushion according to some embodiments, shown in a first position;

[0016] Fig.10 yes Fig. 9 another side view of a portion of the cushion shown in a second position;

[0017] Fig.11 is a front view of a cushion according to some embodiments, shown in a partially disassembled state;

[0018] Fig.12 yes Fig.11 A rear view of the pad;

[0019] Fig.13 is shown after an intermediate assembly step Fig.11 Another rear view of the pad;

[0020] Fig.14 is shown after another assembly step Fig.11 Another rear view of the pad;

[0021] Fig.15 is shown as Figure 11-Figure 14 After the assembly steps Fig.11 A front view of the pad;

[0022] Fig.16 is a side elevation view of a cushion according to some embodiments;

[0023] Fig. 16B A method according to some embodiments is shown;

[0024] Fig. 16C A method according to some embodiments is shown;

[0025] Fig.16D A method according to some embodiments is shown;

[0026] Fig.17 It is a perspective view of a vehicle seat;

[0027] Fig.18A is a front view of a vehicle seat cushion component having plastic mesh side bolsters;

[0028] Fig.18B is a front view of a vehicle seat cushion component having plastic mesh side bolsters;

[0029] Fig.19A is a front view of a vehicle seat cushion component having plastic mesh side bolsters and one or more skin layers;

[0030] Fig.19B is a front view of a vehicle seat cushion component having a plastic mesh side bolster and one or more skin layers;

[0031] Fig. 20 is a perspective view of a vehicle seat incorporating a pair of bolster assemblies sewn to a trim cover;

[0032] Fig.21A is a top view of a vehicle seat component including a pair of bolster assemblies sewn to a trim cover;

[0033] Fig.21B is a cross-sectional view of a vehicle seat component including a pair of bolster assemblies sewn to a trim cover;

[0034] Fig. 22 It is a perspective view of a vehicle seat;

[0035] Fig.23A is a front view of a vehicle seat cushion component having a foamed side bolster;

[0036] Fig. 23B is a front view of a vehicle seat cushion component having foam side bolsters;

[0037] Fig.24A is a front view of a vehicle seat cushion component having a foam side bolster and one or more skin layers;

[0038] Fig. 24B is a front view of a vehicle seat cushion component having a foam side bolster and one or more skin layers;

[0039] Fig.25 is a perspective view of a seat assembly according to some embodiments;

[0040] Fig.26 yes Fig.25 A partial perspective view of a seat assembly without a foam pad;

[0041] Fig. 27 is attached to Fig.25A partial top plan view of a retainer component of a cushion and other seat components;

[0042] Fig.27B A method according to some embodiments is shown;

[0043] Fig.28 shows a perspective view of a seat assembly according to some embodiments;

[0044] Fig.29 A method for communicating with a computer program product according to some embodiments is shown. Fig.28 A partial view of a portion of a cushion used with a seat assembly;

[0045] Fig.30 According to some embodiments, a Fig.29 A schematic diagram of a manufacturing process of a liner;

[0046] Fig.31 Shown for use with Fig.29 A top view of the extrusion direction used in the manufacturing process;

[0047] Fig.32 The invention is shown in a first configuration according to some embodiments. Fig.31 The mold is formed and used with Fig.28 A partial side view schematic diagram of a cushion for use with a seat assembly of the present invention;

[0048] Fig.33 Shown in the second configuration Fig.32 A schematic partial side view of a liner;

[0049] Fig.34 shows an insert Fig.32 A schematic partial side view of a liner;

[0050] Fig.35 Shown for use with Fig.29 A top view of another component or example used in conjunction with a manufacturing process;

[0051] Fig.36 The invention is shown in a first configuration according to some embodiments. Fig.35 The mold is formed and used with Fig.28 A partial side view schematic diagram of a cushion for use with a seat assembly of the present invention;

[0052] Fig.37 Shown in the second configuration Fig.36 A schematic partial side view of a pad; and

[0053] Fig.38 Methods according to some embodiments are shown.

[0054] Detailed Description

[0055] 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.

[0056] It should be understood that the disclosed embodiments are merely exemplary, and that various forms and alternatives are possible. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show 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.

[0057] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0058] It should also be understood that, although in some cases, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first surface can be referred to as a second surface, and similarly, a second surface can be referred to as a first surface without departing from the scope of the various embodiments described. Both the first surface and the second surface are surfaces, but they are not the same surface.

[0059] The terms used in the description of the various embodiments described herein are for the purpose of describing specific embodiments only 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.

[0060] It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. For example, the term "and / or" means that all or only one element of the group may be present. For example, "A and / or B" shall mean "only A, or only B, or both A and B". In the case of "only A", the term also encompasses the possibility that B is not present, that is, "only A, but no B".

[0061] It should be further understood that when used in this specification, the terms “includes,” “including,” “comprises,” and / or “comprising” specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0062] As used herein, the term "if" is optionally interpreted to mean "when" or "after" or "in response to determining" or "in response to detecting," as appropriate to the context. Likewise, the phrases "if it is determined" or "if [the condition or event] is detected" are optionally interpreted to mean "after determining" or "in response to determining" or "after detecting [the condition or event]" or "in response to detecting [the condition or event]," as appropriate to the context.

[0063] Except where expressly indicated in the examples, or otherwise, all numerical quantities in this description indicating the amount of material or the conditions of reaction and / or use should be understood as being modified by the word "about" when describing the broadest scope of the invention. Practice within the stated numerical limits is generally preferred. In addition, unless expressly stated to the contrary: percentages, "portions of..." and ratio values ​​are by weight; the term "polymer" includes "oligomers", "copolymers", "terpolymers" and the like; molecular weights provided for any given polymer refer to weight average molecular weights, unless otherwise indicated; descriptions of a group or class of materials that are suitable or preferred for a given purpose related to the present invention mean that mixtures of any two or more of the members of the group or class are also suitable or preferred; descriptions of ingredients in chemical terms refer to ingredients when added to any combination specified in the description, and do not necessarily exclude chemical interactions between ingredients of the mixture after mixing; the first definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation herein, and applies to common grammatical variations of the initially defined abbreviation after necessary modifications; and unless expressly stated to the contrary, the measurement of a property is determined by the same technique as that mentioned above or below for the same property.

[0064] As used herein, the term "about" means that the amount or value in question can be a specified specific value or some other value in its neighborhood. Typically, the term "about" indicating a value is intended to indicate a range within + / - 5% of that value. As an example, the phrase "about 100" indicates a range of 100+ / -5, i.e., a range from 95 to 105. Typically, when the term "about" is used, it can be expected that similar results or effects according to the present invention can be obtained within a range of + / - 5% of the indicated value.

[0065] It should also be understood that the present invention is not limited to the specific embodiments and methods described below, as specific components and / or conditions may vary of course. In addition, the terminology used herein is used only for the purpose of describing specific embodiments of the present invention and is not intended to be limiting in any way.

[0066] The term "comprising" is synonymous with "including," "having," "containing," or "characterized by." These terms are inclusive and open-ended, and do not exclude additional, undescribed elements or method steps.

[0067] The phrase "consisting of" excludes any element, step, or ingredient not specified in the claim. When the phrase appears in a clause in the body of a claim rather than immediately following the preamble, it is limited only to the elements set forth in that clause; other elements are not excluded from the claim as a whole.

[0068] The phrase "consisting essentially of" limits the scope of a claim to the specified materials or steps, plus those materials or steps that do not materially affect the basic and novel characteristics of the claimed subject matter.

[0069] The phrase “composed of” means “including” or “consisting of.” Generally, this phrase is used to indicate that an object is formed from a material.

[0070] With respect to the terms "comprising," "consisting of," and "consisting essentially of," where one of these three terms is used herein, the presently disclosed subject matter may include the use of either of the other two terms.

[0071] The term "one or more" means "at least one", and the term "at least one" means "one or more". The terms "one or more" and "at least one" include "plurality" and "multiple" as subsets. In specific examples, "one or more" includes "two or more".

[0072] The terms "substantially," "generally," or "about" may be used herein to describe the disclosed embodiments or the claimed embodiments. The term "substantially" may modify a value or relative property disclosed or claimed in the present disclosure. In such cases, "substantially" may mean that the value or relative property it modifies is within ±0%, ±0.1%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, or ±10% of the value or relative property.

[0073] It should also be appreciated that integer ranges explicitly include all intervening integers. For example, integer ranges 1 to 10 explicitly include 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, ranges 1 to 100 include 1, 2, 3, 4, ... 97, 98, 99, 100. Similarly, when any range is required, the difference between the upper and lower limits divided by 10 as the middle number of the increment can be considered as an optional upper or lower limit. For example, if the range is 1.1 to 2.1, the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as the lower or upper limit.

[0074] When referring to numerical quantities, in a specific example, the term "less than" includes a lower non-included limit of 5% of the numerical value indicated after "less than". For example, in a specific example, "less than 20" includes a lower non-included limit of 1. Therefore, this specific example of "less than 20" includes a range between 1 and 20. In another specific example, the term "less than" includes a lower non-included limit of 20%, 10%, 5% or 1% of the numerical value indicated after "less than", in increasing order of preference.

[0075] Seat assemblies and vehicle seat assemblies are designed and manufactured to various specifications including support, comfort, performance, heating, ventilation, cooling, adjustability, etc. Seat assemblies are typically provided with a frame and various foam layers having varying densities to accommodate proper load distribution throughout the seat assembly.

[0076] Figure 1A seat assembly 20 according to an embodiment is shown. The seat assembly 20 is depicted as a vehicle seat that can be used as a seat assembly in a land vehicle, an aircraft, a ship, etc. The seat assembly 20 can be used in any row within a vehicle. Alternatively, the seat assembly 20 can also be used as an office chair or any individual chair. The seat assembly 20 omits traditional foam to improve support and comfort while reducing cost, material, and size. The seat assembly 20 can also use recycled materials that are manufactured for further recycling at the end of the use of the seat assembly 20.

[0077] The seat assembly 20 includes a seat bottom 22, which is sized to accommodate a seated occupant to support the pelvis and thighs of the occupant. The seat assembly 20 also includes a seat back 24, which is sized to extend upright from the seat bottom 22 to support the back of the occupant. A head restraint may also be supported on and above the seat back 24 to support the head of the occupant. The seat bottom 22 is adapted to be supported by a support surface below. For the depicted embodiment, the seat assembly 20 includes a pair of tracks 28 for mounting the seat bottom 22 to the vehicle floor so as to be adjusted forward and backward relative to the vehicle floor. The seat back 24 may also be adjustable to tilt relative to the seat bottom 22. The head restraint may also be adjustable in height, tilt, and forward / rearward directions. As known in the art, other adjustments may be provided.

[0078] The seat bottom 22 includes a frame 30 for providing rigid structural support for the seat bottom 22. The seat back 24 may also include a frame connected to the seat bottom frame 30 to extend upright from the seat bottom 22 and provide rigid structural support for the seat back 24. The frame 30 may be formed of stamped steel alloy, fiber reinforced polymer, or any suitable structural material.

[0079] Conventional seat assemblies include multiple foam layers that collectively provide cushioning on the frame 30. The density of the foam layers varies to provide compliant support to the occupant while distributing forces from the occupant to the frame 30. The foam layers also provide comfort to the occupant. The foam layers are typically molded, so dedicated tools are required for each foam layer of each seat assembly.

[0080] The seat assembly 20 is formed without foam to improve comfort, performance, compactness, and recyclability while reducing manufacturing tooling costs. For example, the seat assembly 20 includes a seat bottom support 36 that provides a seat bottom padding for the seat bottom 22. The seat bottom support 36 is formed from a plurality of stacked layers of non-foam material. The seat back 24 includes a seat back support 38 that is also formed from non-foam stacked layers. Similarly, the headrest may also be provided with a headrest support formed from non-foam stacked layers.

[0081] Figure 1 A plurality of stacked layers 40, 42, 44, 46, 48, 50, 52 are illustrated for constructing the seat bottom support 36, the seat back support 38, and the headrest support. Each of the stacked layers 40, 42, 44, 46, 48, 50, 52 may have a varying material density. The stacked layers 40, 42, 44, 46, 48, 50, 52 may have a material density and firmness that decreases sequentially from the base layer 40 to the intermediate layers 42, 44, 46, 48, 50, and to the comfort layer 52. The stacked layers 40, 42, 44, 46, 48, 50, 52 provide a transition in density and firmness from comfort support at the occupant contact surface at the comfort layer 52 to structural support at the base layer 40.

[0082] For the depicted embodiment, the base layer 40 can be formed of a high density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride. The base layer 40 can provide a substrate or shell for the intermediate layers 42, 44, 46, 48, 50 and the comfort layer 52. The base layer 40 can be mounted directly to the frame 30. The base layer 40 can have a suitable thickness, such as two millimeters or less.

[0083] The stacked layers 40, 42, 44, 46, 48, 50, 52 are Figure 2 4, 46, 48, 50, 52 are shown as multiple sheets. Sheets 40, 42, 44, 46, 48, 50, 52 are each unfolded from a material roll. Sheets 40, 42, 44, 46, 48, 50, 52 are unfolded to be flat. The flatness is roughly planar within the manufacturing tolerance. Each of the material rolls can be a material roll that is easily available on the market, such as materials for vehicle interiors, floorboards, acoustics, etc. Examples of these materials include rubber, thick blankets, needled cotton shoddy, polyethylene terephthalate, linear low-density polyethylene, polypropylene, etc. By utilizing existing materials, material and manufacturing costs are reduced compared to foam pads molded by special tools. The material can also be formed by recycled materials to reduce material costs and reduce waste. According to another embodiment, one or more of the layers 40, 42, 44, 46, 48, 50, 52 can be formed by extruding a thermoplastic resin net, as described in subsequent embodiments.

[0084] After the layers 40, 42, 44, 46, 48, 50, 52 are unfolded into sheets 40, 42, 44, 46, 48, 50, 52, the sheets 40, 42, 44, 46, 48, 50, 52 are then die cut and formed as seat support layers 40, 42, 44, 46, 48, 50, 52 to collectively provide the contours of the seat bottom 22. The seat support layers 40, 42, 44, 46, 48, 50, 52 are then stacked and connected or bonded together. The seat support layers 40, 42, 44, 46, 48, 50, 52 may be welded, sewn, fastened, adhered or otherwise connected to successively adjacent seat support layers 40, 42, 44, 46, 48, 50, 52. Alternatively, the sheets 40, 42, 44, 46, 48, 50, 52 may be stacked prior to the cutting operation, or may be stacked and combined. The cutting operation may be performed by one or more molds. The tooling cost for cutting the molds reduces capital costs compared to dedicated molds. Alternatively, robotic laser cutting or other flexible automation may be employed to reduce tooling costs, which may be programmed to cut a variety of seat arrangements.

[0085] Layers 40, 42, 44, 46, 48, 50, 52 can be customizable. Layers 40, 42, 44, 46, 48, 50, 52 can each be formed with a specific firmness and thickness so that different combinations of layers 40, 42, 44, 46, 48, 50, 52 can be used to optimize specific support and comfort curve profiles for various seats. The comfort curve profile is formed by estimating the pressure distribution of the entire seat assembly 20 based on design features set for the occupant based on the predicted height, weight and other data of the target range of the occupant. The seat assembly 20 using stacked layers 40, 42, 44, 46, 48, 50, 52 instead of polyurethane foam and designed to provide the same static comfort is reduced in weight compared to the same seat assembly made of foam. In addition, stacked layers 40, 42, 44, 46, 48, 50, 52 allow greater design flexibility to reduce pressure in peak areas in the seat assembly 20.

[0086] Figure 3 A seat support 54 is shown according to some embodiments. The shell or base plate 40 may be contoured rather than formed from a flat sheet of material 40. The intermediate layers 42, 44, 46 and the comfort layer 52 are then mounted on the base plate 40.

[0087] Reference again Figure 1Once the stacked layers 40, 42, 44, 46, 48, 50, 52 are assembled, the seat supports 36, 38 are installed in the seat assembly 20. A trim cover 60, 62 is disposed over each seat support 36, 38 to surround and conceal the seat supports 36, 38.

[0088] By eliminating the foam in the seat assembly 20, the molding tool and mold can be eliminated, thereby reducing tooling costs. The flexibility of die cutting, laser cutting or other flexible automation reduces maintenance costs and improves part quality. The recyclability of the material reduces waste. Additionally, the use of chemicals is reduced in the manufacturing process.

[0089] The seat assembly 20 is lighter than similar seats made with foam padding. The seat assembly 20 is also more compact in size, e.g., 35 mm to 40 mm in depth, while providing similar or improved comfort. Layers of targeted comfort are provided and can be easily redesigned for future models or options without additional tooling costs.

[0090] Figure 3B A method 400 is shown according to some embodiments. The method 400 is used to manufacture a seat assembly (e.g., seat assembly 20, 120, 210, 310, 410, 520, 620), which can be a vehicle seat, an office chair, a personal chair, and / or the like. In various examples, the method 400 can have more or fewer steps than described below, and the various steps can be performed in another order, sequentially, or simultaneously. The method 400 can be a method of manufacturing a product, which can be a vehicle seat, an office chair, a personal chair, a cushion, a seat support, a seat bottom cushion, a seat back cushion, a headrest, etc.

[0091] Method 400 includes unrolling (402) a first sheet of a first material, which may be generally planar within manufacturing tolerances, and which may or may not have foam, rubber sheet, thick blanket, needle-punched cotton fabric, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recycled materials, and / or materials each unrolled from a roll of material. Each of the rolls of material may be a roll of material readily available in the market, such as materials for vehicle interiors, floors, audio, etc. Method 400 includes cutting (404) (which may be die-cut, robotic laser-cut, water jet-cut, laser-cut, or other flexible automation) a first seat support layer (e.g., middle layer 42) for a seat bottom, seat back, headrest, etc. from the first sheet, and mounting (406) the first seat support layer (e.g., middle layer 42) on a substrate (e.g., 40), which may be a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the middle layer, and the comfort layer can be contoured rather than formed by a flat sheet. Method 400 includes unfolding (408) a second sheet of a second material, the density of which is less than that of the first material, the second sheet can be roughly planar within manufacturing tolerances, which can provide a transition in density and firmness from the comfort support at the occupant contact surface at the comfort layer to the structural support at the base layer. The second material can have or not have foam, rubber sheet, thick blanket, needle-punched cotton fabric, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recycled materials and / or materials each unfolded from a material roll. Each of the material rolls can be a material roll that is easily available on the market, such as a material for vehicle interiors, floorboards, stereos and / or the like. Method 400 includes, for example, cutting (410) a second seat support layer (e.g., middle layer 44) for a seat bottom, seat back, headrest, and / or the like from a second sheet of material (which may be die cut, robotic laser cut, water jet cut, laser cut, and / or other flexible automation), and mounting (412) the second seat support layer (e.g., middle layer 44) on a first seat support layer (e.g., middle layer 42).

[0092] In some embodiments, method 400 includes unfolding a third sheet of a third material having a density less than that of the second material, the third sheet being substantially planar within manufacturing tolerances, which can provide a transition in density and firmness from comfort support at the occupant contact surface at the comfort layer to structural support at the base layer. The third material may or may not have foam, rubber sheet, thick blanket, needle-punched cotton fabric, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recycled materials, and / or materials each unfolded from a roll of material. Each of the rolls of material may be a roll of material readily available in the market, such as materials for vehicle interiors, floors, audio, and / or the like. Method 400 includes cutting (which may be die-cut, robotic laser-cut, water jet-cut, laser-cut, and / or other flexible automation) a third seat support layer (e.g., middle layer 46) from the third sheet, and mounting the third seat support layer (e.g., middle layer 46) on the second seat support layer (e.g., middle layer 44).

[0093] In some embodiments, method 400 includes bonding a second seat support layer (e.g., middle layer 44) to a first seat support layer (e.g., middle layer 42). The bonding may be provided by a retention clip having an end embedded in the foam and a retention clip end attached to a plastic mesh base, a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a hog ring, a single- or double-sided retention clip, welding, sewing, fastening, adhering, heat staked, and / or otherwise retained.

[0094] A seat assembly (e.g., seat assembly 20) is described, which may be a vehicle seat, an office chair, a personal chair, and / or the like. In some embodiments, a seat assembly (e.g., 20, 120, 210, 310, 410, 520, 620) is manufactured using method 400.

[0095] A seat support (e.g., seat support 36, 38, and / or 54) is described, which may be a seat bottom pad, a seat back pad, a headrest, a headrest, a bolster, a region, a portion, and / or the like. The seat support (e.g., seat support 36, 38, and / or 54) includes a plurality of flat layers (e.g., intermediate layers 42-50), which may be substantially planar within manufacturing tolerances, and which may or may not have foam, rubber sheet, thick blanket, needle-punched cotton fabric, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recycled materials, and / or materials each unrolled from a material roll. Each of the material rolls may be a roll of material readily available in the market, such as materials used for vehicle interiors, floors, stereos, and / or the like. The plurality of planar layers are used to mount to and support an occupant on a seat frame, which may be a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material, wire suspension mats, substrates, and / or panels. The plurality of planar layers (e.g., intermediate layers 42-50) are stacked on top of one another (e.g., as shown in FIG. Figure 2-Figure 3 As shown), and each of the multiple stacked layers has a varying density, which can provide a transition in density and firmness from comfort support at the occupant contact surface at the comfort layer to structural support at the base layer.

[0096] In some embodiments, the density of the plurality of stacked layers (e.g., intermediate layers 42-50) varies in a sequentially increasing manner from the occupant support surface (e.g., layer 52) to the base layer (e.g., layer 42), which can provide a transition in density and firmness from comfort support at the occupant contact surface at the comfort layer to structural support at the base layer, and the plurality of stacked layers can include high-density materials such as elastomers, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the intermediate layer and the comfort layer.

[0097] In some embodiments, the firmness of the plurality of stacked layers (e.g., intermediate layers 42-50) varies in a sequentially increasing manner from the occupant support surface (e.g., layer 52) to the base layer (e.g., layer 42), which can provide a transition in density and firmness from comfort support at the occupant contact surface at the comfort layer to structural support at the base layer, and the plurality of stacked layers can include high-density materials such as elastomers, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the intermediate layer and the comfort layer.

[0098] In some embodiments, multiple stacked layers (e.g., intermediate layers 42-50) are connected together, which connection can utilize the following: a retaining clip (the retaining clip has an end embedded in the layer and a retaining clip end attached to the plastic mesh base), a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a clamp ring, a single-sided or double-sided retaining clip, bonding, welding, sewing, fastening, adhering, heat riveting and / or retaining.

[0099] In some embodiments, each sequential pair (e.g., layers 42 and 44; layers 46 and 48) of a plurality of stacked layers (e.g., intermediate layers 42-50) are bonded together, which may utilize the following: a retaining clip having an end embedded in the layer and a retaining clip end attached to the plastic mesh base, a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a clamp ring, a single-sided or double-sided retaining clip, welding, sewing, fastening, adhering, heat riveting and / or retaining.

[0100] In some embodiments, each sequential pair (eg, layers 42 and 44; layers 46 and 48) in a plurality of stacked layers (eg, intermediate layers 42-50) are welded, stitched, fastened, or adhered together.

[0101] In some embodiments, the plurality of stacked layers (eg, intermediate layers 42 - 50 ) further include rubber, thick blanket, needle-punched cotton, polyethylene terephthalate, or polypropylene.

[0102] In some embodiments, the plurality of stacked layers (e.g., layers 40-50) further include a base layer (e.g., layer 40) adapted to be mounted to a seat frame, wherein the base layer (e.g., layer 40) is formed of a denser material than other layers in the plurality of stacked layers, which may be a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer may provide a substrate or shell for the intermediate layer and / or the comfort layer.

[0103] In some embodiments, the base layer (e.g., layer 40) is formed of an elastomeric material, such as a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the intermediate layer and the comfort layer.

[0104] In some embodiments, the base layer (eg, layer 40) is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the intermediate layer and the comfort layer.

[0105] In some embodiments, the base layer (eg, layer 40) has a thickness of two millimeters or less.

[0106] The techniques described above with respect to method 400 may optionally be combined with one or more elements of the methods described below. For example, the method may be used in conjunction with one or more of methods 1600, 1650, 1680, 2700, 3800.

[0107] A seat assembly (e.g., seat assembly 20) is described, which may be a vehicle seat, an office chair, a personal chair, and / or the like. In some embodiments, the seat assembly (e.g., 20, 120, 210, 310, 410, 520, 620) is manufactured using method 400. The seat assembly includes a substrate (e.g., layer 40) adapted to be mounted to a seat frame, and seat supports (e.g., seat supports 36, 38, and / or 54) are stacked on the substrate.

[0108] In some embodiments, the substrate (e.g., layer 40) can be a high-density material, such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a base or shell for the intermediate layer, and the comfort layer can be formed with a profile rather than being formed by a flat sheet. In some embodiments, the substrate is formed of an elastomeric material, such as a high-density material (such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride). The base layer can provide a base or shell for the intermediate layer and the comfort layer.

[0109] In some embodiments, the substrate (eg, layer 40) is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride.

[0110] In some embodiments, the seat assembly includes a seat frame, which may be a stamped steel alloy, fiber reinforced polymer or any suitable structural material, a wire suspension pad, a substrate and / or a panel, and a substrate (eg, layer 40) attached to the seat frame.

[0111] A seat support (e.g., seat support 36, 38, and / or 54) is described, which may be a seat bottom pad, a seat back pad, a headrest, a head cushion, a bolster, a region, a portion, and / or the like. The seat support (e.g., seat support 36, 38, and / or 54) includes a plurality of flat layers (e.g., layers 40-50), which may be substantially planar within manufacturing tolerances, and which may or may not have foam, rubber sheet, thick blanket, needle-punched cotton fabric, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recycled materials, and / or materials each unrolled from a roll of material. Each of the rolls of material may be a roll of material readily available in the market, such as materials used for vehicle interiors, floors, stereos, and / or the like. A plurality of flat layers for mounting to and for supporting an occupant on a seat frame, which may be a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material, a wire suspension pad, a substrate, and / or a panel, wherein the plurality of flat layers (e.g., layers 40-50) are stacked upon one another, and wherein the density of the plurality of stacked layers (e.g., layers 40-50) varies in a sequentially increasing manner from an occupant support surface (e.g., layer 50) to a substrate layer (e.g., 40), which may provide a transition in density and firmness from comfort support at an occupant contact surface at a comfort layer to structural support at the substrate layer, the plurality of stacked layers may include high density materials such as elastomers, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The substrate layer may provide a substrate or shell for the intermediate layer and the comfort layer.

[0112] Figure 4 The seat assembly 120 is shown as a vehicle seat assembly 120 according to some embodiments. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be used. The seat assembly 120 may be used in a land vehicle, an aircraft, a boat, etc. The seat assembly 120 may also be used in an office chair, a comfort chair, etc.

[0113] The depicted seat assembly 120 includes a seat bottom pad 122 to support the pelvis and thighs of the seated occupant. The seat assembly 120 also includes a seat back pad 124 to support the back and shoulders of the seated occupant. A trim cover 126 is disposed over the seat pads 122, 124 to conceal the seat pads 122, 124 and provide a uniform and smooth contact surface for the occupant.

[0114] Figure 5-Figure 7 A seat bottom cushion 122 is shown disassembled from a seat assembly 120. The seat bottom cushion 122 has an overall one-piece seat cushion 122 design. This design is conventional, as seat cushion designs are typically designed with the final product in mind. Subsequent changes are then incorporated to support the associated manufacturing processes.

[0115] Reference now Figure 8 , a portion of the seat cushion 122 is partially shown as being disassembled from the seat assembly 120. The seat cushion 122 is formed of a plurality of strands 128 or three-dimensional filament loops of an extruded expanded thermoplastic resin or polymer. The seat cushion 122 is also formed with a base layer 130 that is bonded to and / or integrally formed with the plurality of strands 128. The extruded mesh cushion 122 is easily manufactured to have a rectangular cross-section or a uniform thickness.

[0116] Reference again Figure 5-Figure 7 , the seat pad 122 is redesigned into three layers, portions or pad segments 130, 132, 134. The pad segments 130, 132, 134 are collectively stacked on top of each other to collectively provide the seat pad 122. The segments 130, 132, 134 are each designed to have a common maximum thickness so that the segments 130, 132, 134 can be integrally formed as one sheet of the extruded web 128 and subsequently stacked. Additionally, the segments 130, 132, 134 can be pivotally interconnected to be stacked on top of each other. Reference Figure 7 , the outer parallelogram of the central section 132 is designed to pivot upward and cooperate with the lateral outer side surface of the upper section 134.

[0117] Fig. 9 1 shows a side view of a portion of a liner 136 according to an embodiment. The liner 136 includes a pair of liner segments 138, 140 that are integrally formed as a unitary web 128 of extruded thermoplastic resin. A pair of recesses 142 are formed into the surface of the form to define hinges 144 that pivotally connect the liner segments 138, 140. Fig.10 As shown, the cushion segments 138, 140 can pivot about hinge 144. Any number of recesses 142 and any range of pivoting can be used to pivot and / or stack the cushion segments 138.

[0118] Fig.11 A seat back cushion 124 is shown shown partially disassembled. The seat back cushion 124 is formed from a unitary sheet of extruded thermoplastic web 128 having a uniform thickness. The seat back cushion 124 is shown after a secondary molding operation (e.g., cutting to incorporate various cushion details). The cutting operation is performed by automation such as water jet cutting, laser cutting, die cutting, etc. The seat back cushion 124 includes three cushion segments 146, 148, 150.

[0119] The center segment 146 is a forward facing segment of the seat back cushion 124. The upper segment 148 is a rearward facing segment and is pivotally connected to the center segment 146 along a hinge 152. The lower segment 150 is also a rearward facing segment and is pivotally connected to the center segment 146 along a hinge 154 spaced apart from the upper hinge 152.

[0120] Fig.12 The rear side of the liner 124 is shown in the expanded orientation. The exposed surface on the rear side is generally flat to facilitate the mating surfaces of the segments 146, 148, 150. Figure 12 to Figure 13 As shown, the lower section 150 is pivoted about the hinge 154 and is stacked flat on the rear surface of the central section 146. Figure 13 to Figure 14 As shown, the upper section 148 is pivoted about the hinge 152 and stacked flat on the rear surface of the central section 146 .

[0121] The segments 146 , 148 , 150 may then be secured together by heat staking, welding, adhesives, fasteners, hook and loop fasteners, retainers, or the like. Fig.14 The rear surface of the assembled seat back cushion 124 is shown. These segments collectively form a support for attachment to the seat back frame 158 ( Figure 4 ) groove 156. Fig.15 The front surface of the assembled seat back pad 124 is shown.

[0122] The firmness and / or compliance of each seat pad 122, 124 is designed by the number of segments, materials, material density, strand thickness, etc. By providing a common maximum thickness for each segment, a common retainer (such as a trim member) can be attached to any of the segments. The seat pads 122, 124 can be attached directly to the seat frame, or can be attached to a foam support layer, a polyurethane carrier, or any other seat support member.

[0123] Fig.16 A pad 160 according to another embodiment is shown. Similar to the previous embodiments, the pad 160 includes a plurality of integrally formed and pivotally interconnected segments 162, 164, 166. A fastener 168 is provided along the seam between two of the segments 162, 164. The fastener 168 may be a heat rivet, a weld, an adhesive, a hook and loop fastener, a retainer, or the like.

[0124] A seat support (e.g., 122, 124, and / or 136) is described, which can be a seat bottom pad, a seat back pad, a headrest, a head cushion, a bolster, a region, and / or a portion. The seat support (e.g., 122, 124, and / or 136) includes an extruded thermoplastic resin web (the extruded thermoplastic resin web can be an extruded thermoplastic resin web of an extruded expanded thermoplastic resin or a polymer, a strand, a three-dimensional wire loop, a plurality of fused connections in which two loops are attached to each other, and the extruded thermoplastic resin web independently includes 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 ) of multiple layers (e.g., 130, 132, 134, 138, and / or 140), segments, parts, substrates, and / or bolsters for mounting to and supporting an occupant on a seat frame, which may be a stamped steel alloy, fiber reinforced polymer, or any suitable structural material, wire suspension pads, substrates, and / or panels. The multiple layers (e.g., 130, 132, 134, 138, and / or 140) are stacked on top of one another and may be attached using a retaining clip having an end embedded in the foam and a retaining clip end attached to a plastic mesh substrate, a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a clamp ring, a single or double sided retaining clip, bonding, welding, sewing, fastening, adhering, heat riveting, and / or retaining.

[0125] In some embodiments, at least one of the plurality of stacked layers (eg, 130, 132, 134, 138, and / or 140) has a substantially uniform thickness, the at least one stacked layer may have a rectangular cross-section, a uniform thickness, and / or a parallelogram shape.

[0126] In some embodiments, each of the plurality of stacked layers (eg, 130 , 132 , 134 , 138 , and / or 140 ) has a substantially uniform thickness.

[0127] In some embodiments, the seat support (eg, 122, 124, and / or 136) further includes at least two stacked layers (eg, 130, 132, 134, 138, and / or 140).

[0128] In some embodiments, each of the plurality of stacked layers (eg, 162 , 164 , and / or 166 ) are pivotally connected to one another.

[0129] In some embodiments, at least one recess is formed into one of the plurality of stacked layers (eg, 162, 164, 166) to provide a pivot connection.

[0130] In some embodiments, each of the plurality of stacked layers (eg, 162 , 164 , 166 ) is integrally or monolithically formed.

[0131] A seat assembly (e.g., 120) is described, which may be a vehicle seat, an office chair, a personal chair, and / or the like. The seat assembly (e.g., 120) includes a seat frame and a seat support (e.g., 122, 124, and / or 136) attached to the seat frame.

[0132] A seat support (e.g., 122, 124, and / or 136) is described, which can be a seat bottom pad, seat back pad, headrest, head cushion, bolster, region and / or portion. The seat support (e.g., 122, 124, and / or 136) includes multiple layers (e.g., 130, 132, 134, 138, and / or 140), segments, portions, substrates and / or bolsters for mounting to and supporting an occupant on a seat frame, which can be a stamped steel alloy, fiber reinforced polymer, or any suitable structural material, wire suspension pads, substrates and / or panels. Multiple layers (e.g., 130, 132, 134, 138, and / or 140) are stacked on top of one another and may be attached using a retaining clip having an end embedded in the foam and a retaining clip end attached to a plastic mesh base, a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a clamp ring, a single or double sided retaining clip, bonding, welding, sewing, fastening, adhering, heat riveting, and / or retaining. At least one of the multiple stacked layers (e.g., 162, 164, and / or 166) has a substantially uniform thickness, and the at least one stacked layer may have a rectangular cross-section, a consistent thickness, and / or a parallelogram shape. Each of the multiple stacked layers is integrally and / or integrally formed. Each of the multiple stacked layers (e.g., 162, 164, and / or 166) is pivotally connected to one another.

[0133] Fig. 16B A method 1600 is shown according to some embodiments. The method 1600 is used to manufacture a cushion (e.g., cushions 122, 124, 130, 132, 134, 138, and / or 140), which may be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region, and / or a portion. In various examples, the method 1600 may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0134] A method 1600 of manufacturing a product is described, which can be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region and / or a portion. The method 1600 includes forming a thermoplastic resin web (which can be an extruded thermoplastic resin web of an extruded expanded thermoplastic resin or a polymer, a strand, a three-dimensional wire loop, and / or a plurality of fused connections in which two loops are attached to each other, and the extruded thermoplastic resin web independently includes 60% to 95% air by volume and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 ) forming (1602) a plurality of gasket segments (e.g., 130, 132, 134, 138, and / or 140), and stacking (1604) a plurality of gasket segments (e.g., 130, 132, 134, 138, and / or 140) as a gasket (e.g., gaskets 122, 124, and / or 160).

[0135] In some embodiments, method 1600 includes shaping a plurality of gasket segments (eg, 130, 132, 134, 138, and / or 140), which may be cutting, die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automation.

[0136] In some embodiments, method 1600 includes forming a plurality of gasket segments (eg, 162, 164, 166) as a unitary sheet.

[0137] In some embodiments, method 1600 includes folding gasket segments (eg, 162, 164, 166) to stack the gasket segments on top of each other.

[0138] In some embodiments, method 1600 includes forming at least one recess in at least one of a plurality of gasket segments (eg, 162, 164, 166) to fold the gasket segment.

[0139] In some embodiments, method 1600 includes cutting a plurality of gasket segments (eg, 146, 148, 150) to shape the plurality of gasket segments, which shaping may include die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automation.

[0140] A seat support is described, which may be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region and / or a portion. The seat support is manufactured by any of the foregoing or subsequent techniques.

[0141] In some embodiments, method 1600 includes mounting the product to a seat frame, which may be a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material, a wire suspension mat, a substrate, and / or a panel.

[0142] A seat assembly is described, which may be a vehicle seat, an office chair, a personal chair, and / or the like. The seat assembly is manufactured by any of the methods described above or in the following art.

[0143] The techniques described above with respect to method 1600 may optionally be combined with one or more elements of the methods described above and / or below. For example, the method may be used in combination with one or more methods 400, 1650, 1680, 2700, 3800.

[0144] Fig. 16C A method 1650 is shown according to some embodiments. The method 1650 is used to manufacture a cushion (e.g., cushions 122, 124, 130, 132, 134, 138, and / or 140), which may be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region, and / or a portion. In various examples, the method 1650 may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0145] Method 1650 is used to design a seat cushion, which may be a seat bottom cushion, a seat back cushion, a headrest, a headrest, a bolster, a region, and / or a portion. Method 1650 includes obtaining (1652) a design of a unitary seat cushion (e.g., unitary seat cushion 122) and redesigning (1654) the unitary seat cushion design into a plurality of stacked cushion segment designs (e.g., 130, 132, and / or 134), layers, portions, bases, and / or bolsters.

[0146] In some embodiments, method 1650 includes redesigning a monolithic seat cushion design into a plurality of stacked cushion segment designs each having a common maximum thickness.

[0147] The techniques described above with respect to method 1650 may optionally be combined with one or more elements of the methods described above and / or below. For example, the method may be used in combination with methods 400, 1600, 1680, 2700, 3800.

[0148] Fig.16D A method 1680 is shown according to some embodiments. The method 1680 is used to manufacture a seat cushion (e.g., cushions 122, 124, 130, 132, 134, 138, and / or 140), which may be a seat bottom cushion, a seat back cushion, a headrest, a headrest, a bolster, a region, and / or a portion. In various examples, the method 1680 may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0149] Method 1680 includes designing (1682) a plurality of cushion segments according to any of the foregoing or subsequent techniques and forming (1684) the plurality of cushion segments from an extruded thermoplastic resin web, which may be an extruded thermoplastic resin web of an extruded expanded thermoplastic resin or polymer, a strand, a three-dimensional wire loop, and / or a plurality of fused connections in which two loops are attached to each other, the extruded thermoplastic resin web independently comprising 60% to 95% air by volume and having a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 .

[0150] In some embodiments, method 1680 includes stacking a plurality of cushion segments as a cushion, which may be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region, and / or a portion.

[0151] The techniques described above with respect to method 1680 may optionally be combined with one or more elements of the methods described above and / or below. For example, the method may be used in combination with one or more methods 400, 1600, 1650, 2700, 3800.

[0152] refer to Fig.17 , provides a perspective view of a vehicle seat 210 having an extruded plastic mesh base plastic with a mesh bolster. The vehicle seat 210 includes a seat back 212 and a seat bottom 214. The seat back 212 includes a right seat back bolster 216 and a left seat back bolster 218. The seat bottom 214 includes a right seat bottom bolster 220 and a left seat bottom bolster 222.

[0153] Fig.18A and Fig.18BA cross section of a seat support is depicted as a vehicle seat cushion component 230. Advantageously, the vehicle seat cushion component 230 can be a portion of a vehicle seat back 212 or a vehicle seat bottom 214. The vehicle seat component 230 includes a layer that is a plastic mesh substrate 232. The plastic mesh substrate 232 has a first edge 234, a second edge 236, a first face 238, and a second face 240. A first plastic mesh cushion 242 is another layer attached to the plastic mesh substrate 232 at the first edge 234. A second plastic mesh cushion 244 is another layer attached to the plastic mesh substrate 232 at the second edge 236. The first plastic mesh cushion 242 includes a first plurality of three-dimensional wire loops 250 or filaments composed of a first thermoplastic resin or polymer. The second plastic mesh cushion 244 includes a second plurality of three-dimensional wire loops 252 or filaments composed of a second thermoplastic polymer. The first plurality of three-dimensional wire loops 250 and the second plurality of three-dimensional wire loops 252 are each independently shaped into a form suitable for the vehicle seat bolsters 242, 244. The dotted lines surrounding these components highlight the shapes of these bolster components. Similarly, the plastic mesh substrate 232 includes a third plurality of three-dimensional wire loops 254 composed of a third thermoplastic polymer. The third plurality of three-dimensional wire loops 254 are shaped into a generally block-like shape or any shape suitable for use as a cushion. Fig.18A A modification is depicted in which a first plastic mesh pillow 242 is attached to the first edge 234 and a second plastic mesh pillow 244 is attached to the second edge 236, while Fig.18B A refinement is depicted in which a first plastic mesh cushion pillow 242 and a second plastic mesh cushion pillow 244 are each disposed over the first face 238 .

[0154] Fig.19A and Fig.19BA cross section of another variation of a vehicle seat cushion component 230 is depicted. As set forth above, the vehicle seat cushion component 230 may be part of a vehicle seat back 212 or a vehicle seat bottom 214. The vehicle seat component 230 includes a plastic mesh base 232. The plastic mesh base 232 has a first edge 234, a second edge 236, a first face 238, and a second face 240. A first plastic mesh bolster 242 is attached to the plastic mesh base 232 at the first edge 234. A second plastic mesh bolster 244 is attached to the plastic mesh base 232 at the second edge 236. The first plastic mesh bolster 242 includes a first plurality of three-dimensional wire loops 250 comprised of a first thermoplastic polymer. The second plastic mesh bolster 244 includes a second plurality of three-dimensional wire loops 252 comprised of a second thermoplastic polymer. The first plurality of three-dimensional wire loops 250 and the second plurality of three-dimensional wire loops 252 are each independently shaped to fit the form of the vehicle seat bolsters 242, 244. The dashed lines surrounding these components highlight the shapes of these bolster components. Similarly, the plastic mesh substrate 232 includes a third plurality of three-dimensional wire loops 254 composed of a third thermoplastic polymer. The third plurality of three-dimensional wire loops 254 are formed into a generally block-like shape or any shape suitable for use as a cushion. An optional skin layer 256 is disposed on and contacts the first face 238 of the formed plurality of three-dimensional wire loops 254. The vehicle seat component 230 may include one or both of the skin layers 256 and 258.

[0155] refer to Fig.18A , Fig.18B , Fig.19A and Fig.19B , a first plastic mesh pillow 242 is attached to the plastic mesh base 232, and a second plastic mesh pillow 244 is attached to the plastic mesh base 232. These attachments 260 and 262 can be any attachment mechanism known to those skilled in the art, such as Velcro connector strips (hook and loop layers), adhesives, clamp rings, single or double sided retaining clips, etc.

[0156] Examples of methods of forming and properties of the first, second, and third pluralities of three-dimensional wire loops are disclosed in U.S. Patent Nos. 10,233,073 and 9,918,559; the entire disclosures of these U.S. Patents are hereby incorporated by reference in their entirety.

[0157] refer to Fig.18A , Fig.18B , Fig.19A and Fig.19B, at least a subset of the loops in the first plurality of three-dimensional wire loops 250, at least a subset of the loops in the second plurality of three-dimensional wire loops 252, and at least a subset of the loops in the third plurality of three-dimensional wire loops 254 are independently non-parallel or non-aligned with each other. In a refinement, at least a subset of the loops in the first plurality of three-dimensional wire loops 250, at least a subset of the loops in the second plurality of three-dimensional wire loops 252, and at least a subset of the loops in the third plurality of three-dimensional wire loops 254 are independently randomly oriented.

[0158] In a variation, the first plastic mesh pillow 242, the second plastic mesh pillow 244, and the plastic mesh base 232 independently include 60% to 95% air by volume. In some improvements, the first plastic mesh pillow 242, the second plastic mesh pillow 244, and the plastic mesh base 232 independently include at least 60%, 65%, 70%, 75%, or 80% air by volume, preferably in increasing order, and at most 95%, 93%, 90%, 85%, or 80% air by volume, preferably in increasing order. In an improvement, the first plastic mesh pillow 242, the second plastic mesh pillow 244, and the plastic mesh base 232 independently have a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 In some refinements, the plurality of three-dimensional wire loops include a plurality of fused connections 264 in which two loops are attached to each other.

[0159] In a variation, the three-dimensional wire loop 250, the three-dimensional wire loop 252 and the three-dimensional wire loop 254 and any optional skin layer (if present) are independently composed of a thermoplastic polymer. In an improved scheme, the three-dimensional wire loop is an extruded thermoplastic polymer. Examples of thermoplastic polymers include, but are not limited to, polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In an improved scheme, the thermoplastic polymer includes linear low-density polyethylene. In some improved schemes, the three-dimensional wire loop has a fineness of 200 dtex to 10,000 dtex. In an improved scheme, the three-dimensional wire loop has a fineness of 200 dtex to 5,000 dtex. In another improved scheme, the three-dimensional wire loop has a fineness of 200 dtex to 3,000 dtex.

[0160] A vehicle seat cushion (e.g., vehicle seat cushion component 230) is described, which can be a seat bottom cushion, a seat back cushion, a headrest, a headrest, a bolster, a region and / or a portion. The vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a first plastic mesh cushion pillow (e.g., first plastic mesh cushion pillow 242), which can be formed by compression molding, including a first plurality of three-dimensional wire loops (e.g., loops 250), wherein at least a subset of the loops in the first plurality of three-dimensional wire loops can be parallel or aligned with each other, or can be non-parallel or non-aligned with each other, can be randomly oriented, and can have a fineness of 200 dtex to 10,000 dtex. The first plurality of three-dimensional wire loops are composed of a first thermoplastic polymer, the first plurality of three-dimensional wire loops can have 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein each of the first plurality of three-dimensional wire loops can be independently formed into a form for a vehicle seat pillow, the first thermoplastic polymer being a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. A vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a second plastic mesh cushion pillow (e.g., second plastic mesh cushion pillow 244), which can be formed by compression molding, including a second plurality of three-dimensional wire loops (e.g., loops 252), wherein at least a subset of the loops in the second plurality of three-dimensional wire loops can be parallel or aligned with each other, or can be non-parallel or non-aligned with each other, can be randomly oriented, and can have a fineness of 200 dtex to 10,000 dtex. The second plurality of three-dimensional wire loops are composed of a second thermoplastic polymer, the second plurality of three-dimensional wire loops can have 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein each of the second plurality of three-dimensional wire loops can be independently formed into a form for a vehicle seat bolster, the second thermoplastic polymer being a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. A vehicle seat cushion (e.g., a vehicle seat cushion component 230) includes a plastic mesh substrate (e.g., a plastic mesh substrate 232), which can be an extruded expanded thermoplastic resin or an extruded thermoplastic resin mesh of a polymer, a strand, a three-dimensional wire loop, a plurality of fused connections where two loops are attached to each other, the plastic mesh substrate independently comprising 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3The plastic mesh substrate includes a third plurality of three-dimensional wire loops (e.g., loops 254), wherein at least a subset of the loops in the third plurality of three-dimensional wire loops may be parallel or aligned with each other, or may not be parallel or aligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex. The third plurality of three-dimensional wire loops are composed of a third thermoplastic polymer, and the third plurality of three-dimensional wire loops may have 60% to 95% air by volume and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein each of the third plurality of three-dimensional wire loops can be independently formed into a form for a vehicle seat pillow, the third thermoplastic polymer being a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. The plastic mesh substrate can have a block-like shape, and the plastic mesh substrate has a first edge (e.g., first edge 234), a second edge (e.g., second edge 236), a first face (e.g., first face 238), and a second face (e.g., second face 240). The first plastic mesh pillow (e.g., first plastic mesh pillow 242) is attached to the plastic mesh substrate (e.g., plastic mesh substrate 232) at a first edge (e.g., first edge 234), and the second plastic mesh pillow (e.g., second plastic mesh pillow 244) is attached to the plastic mesh substrate (e.g., plastic mesh substrate 232) at a first edge (e.g., first edge 234). These attachments can utilize retaining clips (the retaining clips have ends embedded in the foam and retaining clip ends attached to the plastic mesh base), hook and loop connector strips, hook layers, loop layers, adhesives, clamp loops, single or double sided retaining clips, bonding, welding, sewing, fastening, adhering, heat riveting and / or otherwise retained.

[0161] In some embodiments, a vehicle seat cushion component (eg, vehicle seat cushion component 230 ) is included in a vehicle seat back (eg, vehicle seat back 212 ) or a vehicle seat bottom (eg, vehicle seat bottom 214 ).

[0162] In some embodiments, the first plurality of three-dimensional wire loops (eg, loop 250 ), the second plurality of three-dimensional wire loops (eg, loop 252 ), and the third plurality of three-dimensional wire loops each independently include a plurality of fused connections where two loops are attached to each other.

[0163] In some embodiments, the first plurality of three-dimensional wire loops (eg, loops 250 ) and the second plurality of three-dimensional wire loops (eg, loops 252 ) are each independently shaped into a form for a vehicle seat bolster.

[0164] In some embodiments, a first plastic mesh pillow (eg, first plastic mesh pillow 242) and a second plastic mesh pillow are each disposed over the first side.

[0165] In some embodiments, a first plastic mesh pillow (eg, first plastic mesh pillow 242) is attached to the first edge and a second plastic mesh pillow is attached to the second edge.

[0166] In some embodiments, the first plastic mesh pillow (eg, first plastic mesh pillow 242) and the second plastic mesh pillow are attached to the plastic mesh base (eg, plastic mesh base 232) by hook and loop strips, adhesives, retaining clips, and / or clamp rings.

[0167] In some embodiments, at least a subset of the loops in the first plurality of three-dimensional wire loops (e.g., loop 250), at least a subset of the loops in the second plurality of three-dimensional wire loops (e.g., loop 252), and at least a subset of the loops in the third plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0168] In some embodiments, at least a subset of the loops in the first plurality of three-dimensional wire loops (e.g., loop 250), at least a subset of the loops in the second plurality of three-dimensional wire loops (e.g., loop 252), and at least a subset of the loops in the third plurality of three-dimensional wire loops are randomly oriented.

[0169] In some embodiments, a first skin layer is disposed over a first side of a plastic mesh substrate (eg, plastic mesh substrate 232).

[0170] In some embodiments, the first skin layer is disposed over the second side of the plastic mesh substrate (eg, plastic mesh substrate 232).

[0171] In some embodiments, the first plastic mesh pillow (eg, first plastic mesh pillow 242), the first plastic mesh pillow, and the plastic mesh substrate (eg, plastic mesh substrate 232) independently comprise 60% to 95% air by volume.

[0172] In some embodiments, the first plastic mesh pillow (eg, first plastic mesh pillow 242), the first plastic mesh pillow, and the plastic mesh substrate independently have a viscosity of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

[0173] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extrusion thermoplastic polymer.

[0174] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer each independently include a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0175] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently a linear low density polyethylene.

[0176] In some embodiments, the first plurality of three-dimensional wire loops (eg, loop 250 ), the second plurality of three-dimensional wire loops (eg, loop 252 ), and the third plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0177] A vehicle seat cushion component (e.g., 230) is described, which can be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region and / or a portion. The vehicle seat cushion component (e.g., 230) includes a first plastic mesh cushion pillow (e.g., 242), which can be formed by compression molding, including a first plurality of three-dimensional wire loops (e.g., 250), wherein at least a subset of the loops in the first plurality of three-dimensional wire loops can be parallel or aligned with each other, or can be non-parallel or non-aligned with each other, can be randomly oriented, and can have a fineness of 200 dtex to 10,000 dtex. The first plurality of three-dimensional wire loops are composed of a first thermoplastic polymer, and the first plurality of three-dimensional wire loops can have 60% to 95% air by volume and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein each of the first plurality of three-dimensional wire loops can be independently formed into a form for a vehicle seat pillow, the first thermoplastic polymer being a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. The vehicle seat cushion component (e.g., 230) includes a second plastic mesh pillow (e.g., 244), which can be formed by compression molding, including a second plurality of three-dimensional wire loops (e.g., 252), wherein at least a subset of the loops in the second plurality of three-dimensional wire loops can be parallel or aligned with each other, or can be non-parallel or non-aligned with each other, can be randomly oriented, and can have a fineness of 200 dtex to 10,000 dtex. The second plurality of three-dimensional wire loops are composed of a second thermoplastic polymer, the second plurality of three-dimensional wire loops can have 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3, wherein each of the second plurality of three-dimensional wire loops can be independently formed into a form for a vehicle seat bolster, the second thermoplastic polymer is a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer and / or a linear low-density polyethylene. The vehicle seat cushion component (e.g., 230) includes a plastic mesh substrate (e.g., 232), which can be an extruded expanded thermoplastic resin or an extruded thermoplastic resin mesh of a polymer, a strand, a three-dimensional wire loop, a plurality of fused connections where two loops are attached to each other, the plastic mesh substrate independently including 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 The plastic mesh substrate includes a third plurality of three-dimensional wire loops (e.g., 254), wherein at least a subset of the loops in the third plurality of three-dimensional wire loops may be parallel or aligned with each other, or may not be parallel or aligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex. The third plurality of three-dimensional wire loops are composed of a third thermoplastic polymer, and the third plurality of three-dimensional wire loops may have 60% to 95% air by volume and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein each of the third plurality of three-dimensional wire loops can be independently formed into a form for a vehicle seat pillow, the third thermoplastic polymer being a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. The plastic mesh substrate (e.g., 232) has a first edge, a second edge, a first face, and a second face. The first plastic mesh pillow (e.g., 242) is attached to the plastic mesh substrate (e.g., 232) at the first edge, and the second plastic mesh pillow is attached to the plastic mesh substrate at the first edge. These attachments can utilize a retaining clip (the retaining clip has an end embedded in the foam and a retaining clip end attached to the plastic mesh substrate), a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a clamp ring, a single-sided or double-sided retaining clip, bonding, welding, sewing, fastening, adhering, heat riveting, and / or otherwise retaining. The first plurality of three-dimensional wire loops (eg, 250), the second plurality of three-dimensional wire loops (eg, 252), and the third plurality of three-dimensional wire loops (eg, 254) each independently include a plurality of fused connections where two loops are attached to one another.

[0178] In some embodiments, a vehicle seat cushion component (eg, 230 ) is included in a vehicle seat back or a vehicle seat bottom.

[0179] In some embodiments, the plastic mesh substrate (eg, 232) is 60% to 95% air by volume.

[0180] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer each independently include a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0181] The above techniques may optionally be combined with one or more elements of the methods described above / below. For example, these parts may be used in combination with one or more methods 400, 1600, 1650, 1680, 2700, 3800.

[0182] refer to Fig. 20 , provides a perspective view of a vehicle seat 310 having an extruded plastic mesh substrate. The vehicle seat 310 includes a seat back 312 and a seat bottom 314. The seat back 312 includes a right seat back bolster 316 and a left seat back bolster 318. The seat bottom 314 includes a right seat bottom bolster 320 and a left seat bottom bolster 322. The seat back 312 also includes a seat back frame 324 for mounting a seat back cushion component thereon. Similarly, the seat bottom 314 includes a seat bottom frame 326 for mounting a seat bottom cushion component thereon.

[0183] refer to Fig.21A and Fig.21B , a schematic diagram of a vehicle seat component 330 is provided. The vehicle seat component 330 includes a first bolster assembly 332. The first bolster assembly 332 includes a first core cushion portion 334, layer or segment surrounded by a first outer bolster covering 336 of a first non-woven material. A first bolster trim covering 338 surrounds the first outer bolster covering 336. A second bolster assembly 340 includes a second core cushion portion 342, layer or segment surrounded by a second outer bolster covering 344 of a second non-woven material. A second bolster trim covering 348 surrounds the second outer bolster covering 344. A trim covering portion 350 includes a first edge 352 and a second edge 354. Characteristically, the first bolster assembly 332 is sewn to the trim covering portion at the first edge at a stitching line 356. Similarly, the second bolster assembly 340 is sewn to the trim covering portion at the second edge at a stitching line 358. In a variation, the vehicle seat component 330 also includes a central cushion component 360 positioned in an opening 362 defined by the trim cover portion.

[0184] In an improved solution, the first outer pillow cover 336 and the second outer pillow cover 344 each independently include a non-woven fabric or a woven fabric. For example, the first outer pillow cover 336 and the second outer pillow cover 344 each independently include natural fibers (e.g., jute fibers).

[0185] In a variation, the first bolster assembly 332 and the second bolster assembly 340 are each independently manufactured by compression molding. For example, a layered / sandwich assembly of jute or nonwoven material and a core padding portion may be formed by compression molding. In a refinement, each bolster assembly includes a top jute / nonwoven fabric, a middle padding portion, and a bottom jute / nonwoven fabric.

[0186] In a variation, the trim cover portion defines an opening 362 for receiving the central cushion component 360 .

[0187] In a variation, the first core cushion portion 334, the second core cushion portion 342 and the central cushion component 360 are each independently composed of a foamed polymer. In an improved solution, the first core cushion portion 334 and the second core cushion portion 342 are each independently composed of a foamed polyurethane. As known in the art, the foamed polyurethane is formed by reacting an isocyanate, a polyol and a suitable blowing agent.

[0188] In such Fig.21A and Fig.21B In another variation depicted, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 are each independently composed of a plurality of three-dimensional wire loops or strands composed of a thermoplastic polymer or resin. In a refinement, at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other. In a refinement, the loops in the plurality of three-dimensional wire loops are randomly oriented.

[0189] Still reference Fig.21A and Fig.21BIn another variation, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 each independently include a plurality of three-dimensional wire loops having 60% to 95% air by volume. In some refinements, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 each independently include a plurality of three-dimensional wire loops having at least 60%, 65%, 70%, 75%, or 80% air by volume, preferably in increasing order, and at most 95%, 93%, 90%, 85%, or 80% air by volume, preferably in increasing order. In a refinement, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 independently include a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 In some refinements, the plurality of three-dimensional wire loops includes a plurality of fused connections 364 in which two loops are attached to each other.

[0190] In an improved solution, the three-dimensional wire loop is an extruded thermoplastic polymer. Examples of thermoplastic polymers include, but are not limited to, polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In an improved solution, the thermoplastic polymer includes linear low-density polyethylene. In another improved solution, the thermoplastic polymer is a biodegradable or recyclable polymer (e.g., a "green" polymer).

[0191] In some improvements, the three-dimensional wire loop has a fineness of 200 dtex to 10000 dtex. In an improvement, the three-dimensional wire loop has a fineness of 200 dtex to 5000 dtex. In another improvement, the three-dimensional wire loop has a fineness of 200 dtex to 3000 dtex.

[0192] Examples of methods of forming and properties of multiple three-dimensional wire loops are disclosed in US Pat. Nos. 10,233,073 and 9,918,559; the entire disclosures of which are hereby incorporated by reference in their entirety.

[0193] Advantageously, the above-described seat vehicle seat cushion component 330 improves upon the sustainability of current automotive seat components and provides support to occupants, improving the feel and dampening qualities (related to sound and energy) of extruded plastic mesh components. Specifically, the seat vehicle seat cushion component 330 provides sound insulation for any hard, brittle mesh material that may be added to the component, allows for aggressive contouring and shaping of A-side features, and allows for multiple densities based on layering (top and bottom can have different densities, depending on temperature), temperature cushioning (insulating properties), and consistent feel.

[0194] refer to Fig. 20 , Fig.21A and Fig.21B , a vehicle seat 310 including the above-described seat vehicle seat cushion component 330 is provided. The vehicle seat 310 includes a seat bottom 314 having a seat bottom frame 326 and a seat back 312 attached to the seat bottom 314. The seat back 312 includes a seat back frame 324. The vehicle seat cushion component 330 is attached to the seat back frame 324 and / or the bottom frame 326. As set forth above, the vehicle seat cushion component 330 includes a first bolster assembly 332. The first bolster assembly 332 includes a first core cushion portion 334 surrounded by a first outer bolster cover 336 of a first non-woven material. A first bolster trim cover 338 surrounds the first outer bolster cover 336. A second bolster assembly 340 includes a second core cushion portion 342 surrounded by a second outer bolster cover 344 of a second non-woven material. A second bolster trim cover 348 surrounds the second outer bolster cover 344. The trim cover portion 350 includes a first edge 352 and a second edge 354. Characteristically, the first bolster assembly 332 is stitched to the trim cover portion at the first edge 352 at stitching line 356. Similarly, the second bolster assembly 340 is stitched to the trim cover portion at the second edge 354 at stitching line 358. In a variation, the vehicle seat component 330 also includes a center cushion component 360 positioned in an opening 362 defined by the trim cover portion 350.

[0195] A vehicle seat cushion component (e.g., 330) is described, which can be a seat bottom cushion, a seat back cushion, a headrest, a headrest, a bolster, a region and / or a portion. The vehicle seat cushion component (e.g., 330) includes: a first bolster component (e.g., 332), which can be formed by compression molding and includes a first core cushion portion (e.g., 334), the first core cushion portion can be a foamed polyurethane, a plurality of three-dimensional wire loops composed of a thermoplastic polymer, the first core cushion portion has 60% to 95% air by volume and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , the first core cushion portion is surrounded by a first outer cushion cover (e.g., 336), the first outer cushion cover can be a non-woven fabric, natural fibers and / or jute fibers, the first outer cushion cover is surrounded by a first cushion decorative cover (e.g., 338), the first cushion decorative cover can be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material (vinyl) and / or other materials; a second cushion component (e.g., 340), which can be formed by compression molding and includes a second core cushion portion (e.g., 342), the second core cushion portion can be a foamed polyurethane, a plurality of three-dimensional wire loops composed of a thermoplastic polymer, the second core cushion portion has 60% to 95% air by volume and a density of about 0.01g / cm 3 Up to 0.200g / cm 3 , the second core padding portion is surrounded by a second outer cushion cover (e.g., 344), which may be a non-woven fabric, natural fibers and / or jute fibers; and a decorative covering portion (e.g., 350), which may be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other material, the decorative covering portion having a first edge and a second edge, the first cushion component (e.g., 332) being sewn to the decorative covering portion (e.g., 350) at the first edge, and the second cushion component (e.g., 340) being sewn to the decorative covering portion (e.g., 350) at the second edge.

[0196] In some embodiments, a vehicle seat cushion component (eg, 330 ) is included in a vehicle seat back or a vehicle seat bottom.

[0197] In some embodiments, the first pillow assembly (e.g., 332) and the second pillow assembly (e.g., 340) are each independently formed by compression molding, such as a layered / sandwich assembly of jute or non-woven material and a core padding portion, a top layer of jute / non-woven fabric, a middle padding portion, and a bottom layer of jute / non-woven fabric.

[0198] In some embodiments, the first outer bolster cover (eg, 336) and the second outer bolster cover (eg, 344) each independently comprise a non-woven fabric.

[0199] In some embodiments, the first outer bolster cover (eg, 336) and the second outer bolster cover (eg, 344) each independently include natural fibers.

[0200] In some embodiments, the vehicle seat cushion component (e.g., 330) also includes a central cushion component (e.g., 360), which can be a foamed polyurethane, a plurality of three-dimensional wire loops composed of a thermoplastic polymer, the central cushion component has 60% to 95% air by volume, and / or a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , the central cushion component is positioned in an opening defined by the trim cover portion.

[0201] In some embodiments, the first core cushion portion (eg, 334), the second core cushion portion (eg, 342), and the central cushion component (eg, 360) are each independently constructed of a foamable polyurethane, such as an isocyanate, a polyol, and a suitable blowing agent.

[0202] In some embodiments, the first core pad portion (e.g., 334), the second core pad portion (e.g., 342) and the central pad component (e.g., 360) are each independently composed of a plurality of three-dimensional wire loops, which may be a plurality of fused connections in which two loops are attached to each other, the plurality of three-dimensional wire loops may be non-parallel or non-aligned with each other, the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex, and the plurality of three-dimensional wire loops are composed of a thermoplastic polymer, which may be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer and / or a biodegradable or recyclable polymer.

[0203] In some embodiments, the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to each other.

[0204] In some embodiments, at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0205] In some embodiments, the first core cushion portion (eg, 334), the second core cushion portion (eg, 342), and the central cushion component (eg, 360) independently have 60% to 95% air by volume.

[0206] In some embodiments, the first core cushion portion (e.g., 334), the second core cushion portion (e.g., 342), and the central cushion component (e.g., 360) each independently have a viscosity of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

[0207] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0208] In some embodiments, the thermoplastic polymer includes a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0209] In some embodiments, the thermoplastic polymer is a biodegradable or recyclable polymer.

[0210] In some embodiments, the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0211] In some embodiments, a vehicle seat pad component (eg, 330 ) includes providing sound insulation and thermal buffering.

[0212] A vehicle seat (e.g., 310) is disclosed, which can be a vehicle seat, an office chair, a personal chair, and / or the like. The vehicle seat (e.g., 310) includes: a seat bottom having a seat bottom frame, which can be a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material, wire suspension pads, substrates, and / or panels; a seat back attached to the seat bottom, the seat back including a seat back frame, which can be a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material, wire suspension pads, substrates, and / or panels; and a vehicle seat cushion component (e.g., 330), which can be attached to the vehicle seat cushion component. A vehicle seat cushion component (e.g., 330) includes a first cushion assembly (e.g., 332), the first cushion assembly can be formed by compression molding, and includes a first core cushion portion (e.g., 334), the first core cushion portion can be a foamed polyurethane, a plurality of three-dimensional wire loops composed of a thermoplastic polymer, the first core cushion portion has 60% to 95% air by volume, a density of 0.01 g / cm3 Up to 0.200g / cm 3 , the first core cushion portion is surrounded by a first outer cushion cover (e.g., 336), the first outer cushion cover can be a non-woven fabric, natural fibers and / or jute fibers, the first outer cushion cover is surrounded by a first cushion decorative cover (e.g., 338), the first cushion decorative cover can be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other materials; a second cushion component (e.g., 340)), the second cushion component can be formed by compression molding and includes a second core cushion portion (e.g., 342), the second core cushion portion can be a foamed polyurethane, a plurality of three-dimensional wire loops composed of a thermoplastic polymer, the second core cushion portion has 60% to 95% air by volume and a density of about 0.01g / cm 3 Up to 0.200g / cm 3 , the second core padding portion is surrounded by a second outer cushion cover (e.g., 344), the second outer cushion cover can be a non-woven fabric, natural fibers and / or jute fibers, the second outer cushion cover is surrounded by a second cushion decorative cover, the second cushion decorative cover can be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more pieces of fabric, leather, artificial leather, vinyl material and / or other materials; and a decorative cover portion, the decorative cover portion can be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more pieces of fabric, leather, artificial leather, vinyl material and / or other materials, the decorative cover portion has a first edge and a second edge, the first cushion component (e.g., 332) is sewn to the decorative cover portion at the first edge, and the second cushion component (e.g., 340) is sewn to the decorative cover portion at the second edge.

[0213] In some embodiments, the first outer bolster cover (eg, 336) and the second outer bolster cover (eg, 344) each independently comprise a non-woven fabric.

[0214] In some embodiments, the first outer bolster cover (eg, 336) and the second outer bolster cover (eg, 344) each independently include natural fibers.

[0215] In some embodiments, the vehicle seat cushion component (e.g., 330) also includes a central cushion component (e.g., 360), which can be a foamed polyurethane, a plurality of three-dimensional wire loops composed of a thermoplastic polymer, the central cushion component has 60% to 95% air by volume, and / or a density of about 0.01 g / cm 3 Up to 0.200g / cm 3, the central cushion component is positioned in the opening defined by the trim cover portion.

[0216] In some embodiments, the first core cushion portion (eg, 334), the second core cushion portion (eg, 342), and the central cushion component (eg, 360) are each independently constructed of a foamable polyurethane, such as an isocyanate, a polyol, and a suitable blowing agent.

[0217] In some embodiments, the first core pad portion (e.g., 334), the second core pad portion (e.g., 342) and the central pad component (e.g., 360) are each independently composed of a plurality of three-dimensional wire loops, which may be a plurality of fused connections in which two loops are attached to each other, the plurality of three-dimensional wire loops may be non-parallel or non-aligned with each other, the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex, and the plurality of three-dimensional wire loops are composed of a thermoplastic polymer, which may be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer and / or a biodegradable or recyclable polymer.

[0218] In some embodiments, the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to each other.

[0219] In some embodiments, at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0220] In some embodiments, the first core cushion portion (eg, 334) and the second core cushion portion (eg, 342) are 60% to 95% air by volume.

[0221] In some embodiments, the first core pad portion (eg, 334) and the second core pad portion (eg, 342) each independently have a viscosity of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

[0222] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer, which can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a biodegradable or recyclable polymer.

[0223] The above techniques are optionally combined with one or more elements of the methods described above / below. For example, these parts can be used in combination with one or more methods 400, 1600, 1650, 1680, 2700, 3800.

[0224] refer to Fig. 22 , a perspective view of a vehicle seat 410 having an extruded plastic mesh substrate is provided. The vehicle seat 410 includes a seat back 412 and a seat bottom 414. The seat back 412 includes a right seat back bolster 416 and a left seat back bolster 418. The seat bottom 414 includes a right seat bottom bolster 420 and a left seat bottom bolster 422.

[0225] Fig.23A and Fig. 23B A cross section of a vehicle seat component 430 is depicted. Advantageously, the vehicle seat component 430 is a vehicle seat back or a vehicle seat bottom. The vehicle seat component 430 includes a plastic mesh base 432. The plastic mesh base 432 includes a plurality of three-dimensional wire loops 434 or strands formed of a thermoplastic polymer or resin. In this case, the plurality of three-dimensional wire loops 434 have a generally block-like shape or any shape suitable for use as a cushion. The plastic mesh base 432 has a first edge 442, a second edge 444, a first face 446, and a second face 448. A first foam bolster 450 is attached to the plastic mesh base at the first edge 442. A second foam bolster 452 is attached to the plastic mesh base 432 at the second edge 444. Fig.23A A modification is depicted in which a first foam bolster 450 is attached to the first edge 442 and a second foam bolster 452 is attached to the second edge 444, while Fig. 23B A refinement is depicted in which a first foam bolster 450 and a second foam bolster 452 are each disposed above the first face 446 .

[0226] Fig.24A and Fig. 24B Describes another variation of the cross-section of the cushion portion of the vehicle seat. As explained above, the vehicle seat component 430 is a vehicle seat back or a vehicle seat bottom. The vehicle seat component 430 includes a plastic mesh base 432. The plastic mesh base 432 includes a plurality of three-dimensional wire loops 434 or strands formed by a thermoplastic polymer or resin. The plastic mesh base 432 has a first edge 442, a second edge 444, a first face 446, and a second face 448. A first foam bolster 450 is attached to the plastic mesh base 432 at the first edge 442. A second foam bolster 452 is attached to the plastic mesh base 432 at the second edge 444. In this variation, an optional skin layer 456 is disposed on and contacts the first face 446 of the plurality of 434 three-dimensional wire loops 434 formed. The optional skin layer 456 is disposed on and contacts the first face 446 of the plurality of 434 three-dimensional wire loops formed. Vehicle seat component 430 may include one or both of skin layers 456 and 458 .

[0227] refer to Fig.23A , Fig. 23B , Fig.24A and Fig. 24B The first foaming cushion 450 and the second foaming cushion 452 are each independently made of a foaming polymer. In an improved solution, the first foaming cushion 450 and the second foaming cushion 452 are each independently made of a foaming polyurethane. As known in the art, the foaming polyurethane is formed by reacting an isocyanate, a polyol and a suitable blowing agent.

[0228] refer to Fig.23A , Fig. 23B , Fig.24A and Fig. 24B , the first foam bolster 450 is attached to the plastic mesh base 432 using a first retaining clip 460, and the second foam bolster 452 is attached to the plastic mesh base 432 using a second retaining clip 462. The first retaining clip 460 and the second retaining clip 462 each independently have an end embedded in the foam and a retaining clip end attached to the plastic mesh base. Examples of retaining clips are disclosed in U.S. Patent Application No. 17 / 724,866, the entire disclosure of which is hereby incorporated by reference.

[0229] Examples of methods of forming and properties of multiple three-dimensional wire loops are disclosed in U.S. Patent Nos. 10,233,073 and 9,918,559; the entire disclosures of these U.S. Patents are hereby incorporated by reference in their entireties.

[0230] refer to Fig.23A , Fig. 23B , Fig.24A and Fig. 24B , at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other. In a refinement, the loops in the plurality of three-dimensional wire loops are randomly oriented, and the plastic mesh substrate has 60% to 95% air by volume. In a refinement, the plastic mesh substrate has about 0.01 g / cm 3 Up to 0.200g / cm 3 In some refinements, the plurality of three-dimensional wire loops include a plurality of fused connections 464 in which two loops are attached to each other.

[0231] In a variation, the three-dimensional wire loop and the optional skin layer (if present) are composed of a thermoplastic polymer. In an improved scheme, the three-dimensional wire loop is an extruded thermoplastic polymer. Examples of thermoplastic polymers include, but are not limited to, polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In an improved scheme, the thermoplastic polymer includes linear low-density polyethylene. In some improved schemes, the three-dimensional wire loop has a fineness of 200 dtex to 10,000 dtex. In an improved scheme, the three-dimensional wire loop has a fineness of 200 dtex to 5,000 dtex. In another improved scheme, the three-dimensional wire loop has a fineness of 200 dtex to 3,000 dtex.

[0232] A vehicle seat cushion component (e.g., 430) is described, which can be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region and / or a portion. The vehicle seat cushion component (e.g., 430) includes: a plastic mesh substrate (e.g., 432), which can be an extruded thermoplastic resin mesh of an extruded expanded thermoplastic resin or a polymer, a strand, a three-dimensional wire loop, a plurality of fused connections in which two loops are attached to each other, the plastic mesh substrate independently including 60% to 95% air by volume, a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 The plastic mesh substrate (e.g., 432) includes a plurality of three-dimensional wire loops, wherein at least a subset of the loops in the plurality of three-dimensional wire loops may be parallel or aligned with each other, or may not be parallel or aligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex. The three-dimensional wire loops are composed of a thermoplastic polymer, and the three-dimensional wire loops may have 60% to 95% air by volume and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3, wherein each of the three-dimensional wire loops can be independently formed into a form for a vehicle seat bolster, the thermoplastic polymer is a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. The plastic mesh substrate (e.g., 432) has a first edge, a second edge, a first face that can be a skin layer, and a second face that can be a skin layer. A vehicle seat cushion component (e.g., 430) includes a first foam bolster (e.g., 450) and a second foam bolster (e.g., 452), wherein the first foam bolster may be a foamed polymer, foamed polyurethane, isocyanate, polyol and / or a suitable blowing agent, the first foam bolster being attached to a plastic mesh base (e.g., 432) at a first edge, the attachment being with or without a retaining clip having an end embedded in the foam and a retaining clip end attached to the plastic mesh base, a hook and loop connector strip, a hook layer, a loop layer, an adhesive, a clamp ring, a single-sided or double-sided retaining clip, bonding, welding, sewing, fastening, adhering, heat riveting and / or otherwise retained, and the second foam bolster may be a foamed polymer, foamed polyurethane, isocyanate, polyol and / or a suitable blowing agent, the second foam bolster being attached to the plastic mesh base (e.g., 432) at a second edge.

[0233] In some embodiments, a vehicle seat cushion component (eg, 430 ) is included in a vehicle seat back or a vehicle seat bottom.

[0234] In some embodiments, the plurality of three-dimensional wire loops comprises a plurality of fused connections in which two loops are attached to each other, which two loops may be parallel or aligned with each other, or may be non-parallel or non-aligned with each other, and / or randomly oriented.

[0235] In some embodiments, the first foam bolster (eg, 450) and the second foam bolster (eg, 452) are each independently comprised of a foamed polymer, which may be a foamed polyurethane.

[0236] In some embodiments, the first foam bolster (eg, 450) and the second foam bolster (eg, 452) are each independently comprised of foamed polyurethane, which may be a foaming polymer, an isocyanate, a polyol, and / or a suitable blowing agent.

[0237] In some embodiments, the first foam bolster (eg, 450) and the second foam bolster (eg, 452) are each at least partially disposed over the first face.

[0238] In some embodiments, a first foam bolster (eg, 450) is attached to the first edge and a second foam bolster (eg, 452) is attached to the second edge.

[0239] In some embodiments, a first foam bolster (e.g., 450) is attached to a plastic mesh base (e.g., 432) using a first retaining clip, and the first foam bolster (e.g., 450) is attached to a plastic mesh base (e.g., 432) using a second retaining clip, the first retaining clip and the second retaining clip each having an end embedded in the foam of the corresponding first foam bolster or second foam bolster (e.g., 452), and a retaining clip end attached to the plastic mesh base (e.g., 432).

[0240] In some embodiments, at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0241] In some embodiments, the loops in the plurality of three-dimensional wire loops are randomly oriented.

[0242] In some embodiments, the plastic mesh substrate (eg, 432) is 60% to 95% air by volume.

[0243] In some embodiments, the plastic mesh substrate (eg, 432) has a viscosity of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

[0244] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0245] In some embodiments, the thermoplastic polymer includes a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0246] In some embodiments, the thermoplastic polymer comprises linear low density polyethylene.

[0247] In some embodiments, the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0248] A vehicle seat cushion component (e.g., 430) is disclosed, which can be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region and / or a portion. The vehicle seat cushion component includes a plastic mesh substrate (e.g., 432), which can be an extruded thermoplastic resin mesh of an extruded expanded thermoplastic resin or a polymer, a strand, a three-dimensional wire loop, a plurality of fused connections in which two loops are attached to each other, the plastic mesh substrate independently includes 60% to 95% air by volume, and the density of the plastic mesh substrate is 0.01 g / cm 3 Up to 0.200g / cm 3The plastic mesh substrate (e.g., 432) includes a plurality of three-dimensional wire loops, wherein at least a subset of the loops in the plurality of three-dimensional wire loops may be parallel or aligned with each other, or may not be parallel or aligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex, the three-dimensional wire loops are composed of a thermoplastic polymer, the three-dimensional wire loops may have 60% to 95% air by volume, and a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein each of the three-dimensional wire loops can be independently formed into a form for a vehicle seat pillow, and the thermoplastic polymer is a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer and / or a linear low-density polyethylene.

[0249] In some embodiments, a vehicle seat cushion component (eg, 430 ) is included in a vehicle seat back or a vehicle seat bottom.

[0250] In some embodiments, the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to each other.

[0251] In some embodiments, the loops in the plurality of three-dimensional wire loops are randomly oriented.

[0252] In some embodiments, the plastic mesh substrate (eg, 432) is 60% to 95% air by volume.

[0253] In some embodiments, the thermoplastic polymer includes a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0254] The above techniques may optionally be combined with one or more elements of the methods described above / below. For example, these parts may be used in combination with another method 400, 1600, 1650, 1680, 2700, 3800.

[0255] Fig.25 A seat assembly 520 according to an embodiment is shown. The seat assembly 520 is depicted as a vehicle seat that can be used as a seat assembly in vehicles such as land vehicles, aircraft, ships, etc. The seat assembly 520 can be used as a personal chair or a bench chair in any row within the vehicle. Alternatively, the seat assembly 520 can also be used as an office chair or any other chair. The seat assembly 520 omits traditional foam to improve support and comfort. The seat assembly 520 also optionally uses recycled materials that are manufactured for further recycling at the end of the use of the seat assembly 520.

[0256] The seat assembly 520 includes a seat bottom 522, which is sized to receive a seated occupant to support the pelvis and thighs of the occupant. The seat assembly 520 also includes a seat back 524, which is sized to extend upright from the seat bottom 522 to support the back of the occupant. A headrest (or head cushion) 526 can also be supported on and above the seat back 524 to support the head of the occupant. The seat bottom 522 is adapted to be supported by a support surface below. For the depicted embodiment, the seat assembly 520 includes a pair of tracks 528 for mounting the seat bottom 522 to the vehicle floor so as to be adjusted forward and backward relative to the vehicle floor. The seat back 524 can also be adjustable to tilt relative to the seat bottom 522. Although in the depicted embodiment, the headrest 526 is shown as integrated with the seat back 524 and integral with the seat back 524, in some embodiments, the headrest 526 can be separated and therefore adjustable in height, inclination and front / rear direction. Other adjustments may be provided as known in the art.

[0257] The seat bottom 522 may include a frame (not shown) for providing rigid structural support to the seat bottom 522. Similarly, the seat back 524 may also include a frame (not shown) connected to the seat bottom frame to extend upright from the seat bottom 522 and provide rigid structural support to the seat back 524. In some embodiments, a single (single-piece) frame is optionally used for both the seat bottom 522 and the seat back 524 to provide rigid structural support. These / such frames are optionally formed of stamped steel alloys, fiber reinforced polymers, or any suitable structural material.

[0258] Conventional seat assemblies include multiple foam layers that collectively provide cushioning on a frame. The density of the foam layers varies to provide compliant support to the occupant while distributing forces from the occupant to the frame. The foam layers also provide comfort to the occupant. However, some non-foam materials have been found to improve support, comfort, performance, and compactness while facilitating potential recycling of the material at the end of the use of the seat assembly. Therefore, the present disclosure relates to the use of non-foam materials to provide cushioning on a frame.

[0259] Still reference Fig.25 , the seat bottom 522 and the seat back 524 of the seat assembly 520 optionally further include one or more seat bottom cushions 530 and one or more seat back cushions 532. One or more seat bottom cushions 530, one or more seat back cushions 532, or both may include a non-foam material. In some embodiments, the non-foam material of one or more seat bottom cushions 530, one or more seat back cushions 532, or both may optionally be one or more twisted mesh materials.

[0260] Reference now Fig.26 , one of the seat bottom pads 530 is partially shown as being disassembled from the seat assembly 520. The seat bottom pad 530 can be, but need not be, identical to one or more seat back pads 532, and can be formed of a plurality of strands 534 or loops of extruded expanded thermoplastic resin. In some embodiments, the seat bottom pad 530 is also optionally formed with or bonded to at least one layer (or film) 536, which is formed with or bonded to a plurality of strands 534. Layer 536 can be joined to the plurality of strands 534 when the thermoplastic resin is cured or via other coupling means such as compression molding, adhesives, mechanical fasteners (e.g., clamps, clamp rings, deflected angled ribbed shank fasteners (also known as Christmas tree fasteners), hook and loop fasteners, etc.), stitching, etc. In some embodiments, layer 536 is optionally also an extruded thermoplastic resin material, a non-woven material, or both. In an exemplary embodiment, the non-woven material of layer 536 optionally includes jute, which is a biodegradable plant fiber.

[0261] refer to Fig. 27 , layer 536 optionally provides a surface for attaching other seat components 538, 540 by adhesive, mechanical fasteners (e.g., clamps, clamp rings, Christmas tree fasteners, hook and loop fasteners, etc.), or the like. In the depicted embodiment, the other seat components 538, 540 are attached to layer 536 by clamping rings 542 (also referred to as clamp rings 542). These other seat components 538, 540 are optionally one or more of the following: a trim cover, an actuator such as an air bag assembly, a heat transfer layer such as a heating pad, etc.

[0262] For the depicted embodiment, the clamp ring 542 attached to the compression molded jute 536 and expanded thermoplastic resin mesh 534 provides a suitable attachment to resist tension. For example, this embodiment withstands tensile loads of at least 50 Newtons and up to 151 Newtons, with a deformation of at least 26 mm and up to 44 mm.

[0263] Therefore, a seat assembly comprising a seat bottom, a seat back and a seat trim assembly is disclosed herein, wherein the seat trim assembly is optionally located in the seat bottom, the seat back or both. Optionally, the seat trim assembly disclosed herein also includes at least one fabric and at least one retainer, at least one fabric is sized to be displaced on the surface of a cushion, and at least one retainer is connected to at least one fabric along the periphery of the fabric to receive a decorative component. In some embodiments, the seat trim assembly also includes a cushion, which optionally includes a twisted mesh material. Similarly, in some embodiments, the seat trim assembly also includes a decorative cover, which is sized to at least partially surround the cushion and at least one fabric, so that the decorative cover is connected to at least one retainer. At least one retainer can be directly or indirectly connected to the cushion, the decorative component or the decorative cover.

[0264] The decorative component of the seat trim assembly can be an actuator such as an air bag assembly, a heat transfer layer such as a heating pad, or any combination thereof. The retainer of the seat trim assembly can be one or more of at least one clamping ring, a clamp ring, a Christmas tree fastener, a hook and loop fastener, etc., or any combination thereof. At least one fabric of the seat trim assembly can be any non-woven material, fabric, textile, or any combination thereof. In some embodiments, the non-woven material of at least one fabric also includes jute.

[0265] In some embodiments of the present disclosure, a seat assembly is disclosed, which includes a seat bottom, a seat back, and a product formed by a method comprising the following steps, wherein the product can be located in the seat bottom, the seat back, or both. These steps are optionally connecting at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a cushion, and connecting a decorative component to at least one retainer. In some embodiments, the method also includes compression molding at least one fabric into the contour of the cushion before stacking at least one fabric on the cushion. In other embodiments, before stacking at least one fabric on the cushion, at least one fabric can be connected to the contour of the cushion via an adhesive, a mechanical fastener (such as a clamp, a clamp ring, a Christmas tree fastener, a hook and loop fastener, etc.), or the like. At least one retainer can be directly or indirectly connected to at least one retainer. In an exemplary embodiment where at least one retainer is a clamping ring, another step of the method is clamping at least one clamping ring to the fabric. In some embodiments, stacking at least one fabric on the cushion also optionally includes stacking at least one fabric on a twisted mesh material cushion.

[0266] In some embodiments, the product formed by the foregoing method further comprises a decorative cover sized to at least partially surround the pad and at least one fabric coupled to at least one retainer. In some exemplary embodiments, the decorative component of the product formed by the method may be an actuator such as an airbag assembly, a heat transfer layer such as a heating pad, or any combination thereof. The retainer of the product formed by the method may be at least one clamping ring, a clamp ring, a Christmas tree fastener, a hook and loop fastener, or the like, or any combination thereof. The at least one fabric of the product formed by the method may be any non-woven material, fabric, textile, or any combination thereof. In some exemplary embodiments, the non-woven material of at least one fabric further comprises jute.

[0267] According to other aspects of the present disclosure, a decorative assembly manufactured by the following method is disclosed. The method includes coupling at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a pad, and coupling a decorative component (such as an actuator, a heat transfer layer, or any combination thereof) to at least one retainer. In some embodiments, the method optionally also includes at least partially surrounding the pad and at least one fabric by coupling a decorative cover to at least one retainer. At least one retainer that can be directly or indirectly coupled to at least one fabric, pad, or decorative component is optionally one or more of at least one clamping ring, a clamp ring, a Christmas tree fastener, a hook and loop fastener, etc., or any combination thereof. At least one fabric of the decorative assembly manufactured by the aforementioned method can be any non-woven material, fabric, textile, or any combination thereof. In some embodiments, the non-woven material of at least one fabric also includes jute.

[0268] A component (e.g., seat component 520) is described, which can be a vehicle seat, an office chair, a personal chair, and / or the like. The component (e.g., 520) includes at least one fabric, which can be a non-woven material, a biodegradable plant fiber, jute, and / or an extruded thermoplastic resin material. The at least one fabric is sized to be displaced on the surface of a cushion (e.g., 530 and / or 532), the cushion can be a twisted mesh material, a ring of extruded expanded thermoplastic resin, an extruded expanded thermoplastic resin or an extruded thermoplastic resin mesh of a polymer, a strand, a three-dimensional wire ring, a plurality of fused connections in which two rings are attached to each other, the cushion independently includes 60% to 95% air by volume, and the density of the cushion is about 0.01 g / cm 3 Up to 0.200g / cm 3At least one retainer (e.g., 542) can be a clamping ring (not directly coupled to the cushion), a clamp ring, an angled ribbed shank fastener, a hook and loop fastener, a stitching, an adhesive, a weld, a rivet, a connector strip, a retaining clip, a clamp, a barb fastener, a laminate, and / or a compression molding, and at least one retainer is coupled to at least one fabric along the perimeter of the fabric to receive a decorative component (e.g., 538 and / or 540), which can be a decorative cover, a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other materials, an actuator such as an air bag assembly (e.g., 538 and / 540), a heat transfer layer such as a heating pad (e.g., 538 and / 540), or any combination thereof.

[0269] In some embodiments, the assembly includes a gasket (eg, 530 and / or 532).

[0270] In some embodiments, the pad (e.g., 530 and / or 532) further comprises a twisted mesh material, which may be an extruded thermoplastic resin mesh, a strand, a three-dimensional wire loop, a plurality of fused connections in which two loops are attached to each other, of an extruded expanded thermoplastic resin or a polymer, the twisted mesh material independently comprising 60% to 95% air by volume, the density of the twisted mesh material being about 0.01 g / cm 3 Up to 0.200g / cm 3 , wherein at least a subset of the loops in the plurality of three-dimensional wire loops may be parallel or aligned with each other or may not be parallel or aligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex.

[0271] In some embodiments, the assembly includes a decorative cover, which may be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other material, the decorative cover being sized to at least partially surround a cushion (e.g., 530 and / or 532) and at least one fabric, wherein the decorative cover is coupled to at least one retainer.

[0272] In some embodiments, at least one retainer (eg, 542) includes at least one clamping ring (eg, 542).

[0273] In some embodiments, at least one retainer (eg, 542) is not directly coupled to a cushion (eg, 530 and / or 532).

[0274] In some embodiments, at least one of the fabrics further comprises a nonwoven material.

[0275] In some embodiments, the nonwoven material further comprises jute.

[0276] A seat assembly is described, which may be a vehicle seat, an office chair, a personal chair, and / or the like. The seat assembly includes a seat bottom, a seat back, and a seat trim assembly located in the seat bottom or the seat back. The seat trim assembly may be a trim cover, a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other materials.

[0277] A product is described which may be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region and / or a portion. The product is formed by a method comprising: coupling at least one retainer (e.g., 542) to the periphery of at least one fabric, the at least one retainer being a clamping ring (which is not directly coupled to the pad), a clamp ring, a deflected angled ribbed shank fastener, a hook and loop fastener, a suture, an adhesive, a weld, a rivet, a connector strip, a retaining clip, a clamp, a barb fastener, a laminate and / or a compression molded part, the at least one fabric being a non-woven material, a biodegradable plant fiber, jute and / or an extruded thermoplastic resin material; stacking at least one fabric on a pad (e.g., 530 and / or 532), the pad being a twisted mesh material, a ring of an extruded expanded thermoplastic resin, an extruded expanded thermoplastic resin or an extruded thermoplastic resin mesh of a polymer, a strand, a three-dimensional wire ring, a plurality of fused connections in which two rings are attached to each other, the pads independently comprising 60% to 95% air by volume, the density of the pads being about 0.01 g / cm 3 Up to 0.200g / cm 3 ; and connecting a decorative component (which may be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other material, may be an actuator of an air bag assembly, may be a heat transfer layer of a heating pad, or any combination thereof) to at least one retainer (e.g., 542), the connection utilizing or not utilizing a retainer, a clamping ring (which is not directly coupled to a pad), a clamping ring, an angled ribbed shank fastener, a hook and loop fastener, a suture, an adhesive, a weld, a rivet, a connector strip, a retaining clip, a clamp, a barb fastener, a laminate and / or a compression molded part).

[0278] In some embodiments, the method further includes compression molding the at least one fabric to the contour of the cushion (e.g., 530 and / or 532) prior to stacking the at least one fabric on the cushion (e.g., 530 and / or 532).

[0279] In some embodiments, the method also includes connecting a decorative cover (which may be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other material, which is sized to at least partially surround the cushion (e.g., 530 and / or 532) and at least one fabric) to the at least one retainer (e.g., 542), the connection utilizing or not utilizing a retainer, a clamping ring (which is not directly coupled to the cushion), a clamp ring, an angled ribbed shank fastener, a hook and loop fastener, a stitching, an adhesive, a weld, a rivet, a connector strip, a retaining clip, a clamp, a barb fastener, a laminate and / or a compression molding.

[0280] In some embodiments, stacking at least one fabric on a pad (eg, 530 and / or 532) further comprises stacking at least one fabric on a twisted mesh material pad.

[0281] In some embodiments, the method further includes not directly coupling at least one retainer (eg, 542 ) to the cushion (eg, 530 and / or 532 ).

[0282] In some embodiments, the method further includes clamping at least one clamping ring to the fabric as at least one retainer (eg, 542).

[0283] A seat assembly is described, which may be a vehicle seat, an office chair, a personal chair, and / or the like. The seat assembly includes a seat bottom, a seat back, and a product formed according to any of the foregoing or subsequent techniques located in the seat bottom or the seat back.

[0284] Fig.27B Method 2700 is shown according to some embodiments. Method 2700 is used to couple a retainer (e.g., 542) (such as a clamping ring (which is not directly coupled to a pad), a clamp ring, a deflected angled ribbed shank fastener, a hook and loop fastener, a suture, an adhesive, a weld, a rivet, a connector strip, a retaining clip, a clamp, a barb fastener, a laminate, and / or a compression molded part) to a fabric, which may be a non-woven material, a biodegradable plant fiber, jute, and / or an extruded thermoplastic resin material. In various examples, method 2700 may have more or fewer steps than described below, and the various steps may be performed in another order, sequentially, or simultaneously.

[0285] Method 2700 includes connecting (2702) at least one retainer (e.g., 542) (the connection utilizing or not utilizing a retainer, a clamping ring (which is not directly connected to a pad), a clamp ring, an angled ribbed shank fastener, a hook and loop fastener, stitching, an adhesive, a weld, a riveting, a connector strip, a retaining clip, a clamp, a barb fastener, a laminate and / or a compression molding) to the periphery of at least one fabric, at least one fabric can be a non-woven material, a biodegradable plant fiber, jute and / or an extruded thermoplastic resin material. The method 2700 includes stacking (2704) at least one fabric on a pad (e.g., 530 and / or 532), the pad being a twisted mesh material, a ring of an extruded expanded thermoplastic resin, an extruded expanded thermoplastic resin or an extruded thermoplastic resin mesh of a polymer, a strand, a three-dimensional wire ring, a plurality of fused connections where two rings are attached to each other, the pad independently comprising 60% to 95% air by volume, the pad having a density of about 0.01 g / cm 3 Up to 0.200g / cm 3 The method 2700 includes coupling (2706) a decorative component (which may be a nonwoven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other material, an actuator of an air bag assembly, a heat transfer layer of a heating pad, or any combination thereof) to at least one retainer (e.g., 542).

[0286] In some embodiments, method 2700 includes at least partially enclosing a cushion (e.g., 530 and / or 532) and at least one fabric by connecting a decorative cover (which may be a non-woven material, biodegradable plant fibers, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other material) to at least one retainer (e.g., 542).

[0287] In some embodiments, at least one of the fabrics further comprises a nonwoven material.

[0288] A decorative component is described, which can be a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other materials. The decorative component is made by any of the methods of the foregoing or subsequent techniques.

[0289] The above techniques are optionally combined with one or more elements of the methods described above / below. For example, these parts can be used in combination with one or more methods 400, 1600, 1650, 1680, 3800.

[0290] refer to Fig.28, seat assembly 620 is illustrated, such as vehicle seat assembly 620. In other examples, seat assembly 620 can be shaped and sized to be used as a front driver seat or front passenger seat, second row seat, third row seat or other rear seat, and can include a bench seat as shown, a bucket seat or other seat styles. In addition, seat assembly 620 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. Additionally, seat assembly 620 can be configured to be used with other non-vehicle applications.

[0291] The seat assembly 620 has a frame 622 or other support structure. The seat assembly has seat components, and these seat components include at least a seat bottom 624 and a seat back 626. The seat bottom 624 can be sized to receive a seated occupant to support the pelvis and thighs of the occupant. The seat back 626 can be sized to extend upright from the seat bottom 624 to support the back of the occupant. The seat assembly 620 can additionally have a headrest 627, wherein the headrest 627 is shown only for adjacent seat assemblies.

[0292] The seat assembly 620 has a cushion 640 that defines a seat bottom cushion area 628 for the seat bottom 624 and a seat back cushion area 630 for the seat back 626. The frame 622 may include a wire suspension pad or other structure to support the cushion 640. The cushion 640 is described in more detail below according to various examples and embodiments.

[0293] The frame 622 provides rigid structural support for the seat components (e.g., cushion 640, seat bottom 624, and seat back 626), and can be configured as a plurality of frame members that can move relative to each other to provide adjustment of the seat assembly. The frame can be formed of stamped steel alloy, fiber reinforced polymer, or any suitable structural material. The frame 622 can also include a substrate (e.g., a panel) to support the cushion 640.

[0294] One or more trim covers 632 are used to cover the cushion 640 and provide a seating surface 654 for the seat assembly 620. The vehicle seat assembly 620 is shown without a trim cover, and the adjacent seat assembly shows a trim cover 632. In one example, the trim cover 632 covers both the cushion areas 628, 630. In other examples, multiple trim covers are provided to cover the seat bottom cushion area and the seat back cushion area. The trim cover 632 can be formed from one or more pieces of fabric, leather, leatherette, vinyl material, or other materials.

[0295] In the example shown, the seat cushion 640 includes at least one non-foam component or member 642. In one example, and as shown, the seat cushion 640 is formed only by the member 642, so that the non-foam component 642 provides all the cushioning for the seat component between the frame 622 and the trim cover 632. In other examples, the seat cushion 640 can be formed by the member 642 and one or more foam components (such as components formed of molded polyurethane foam) and / or one or more non-foam components (such as auxiliary components 648 described below). The seat cushion 640 can have non-foam components and foam components, and the non-foam components and foam components are positioned to provide different areas of the cushion 640 (e.g., the center area and the side bolster areas) for the seat component. Alternatively or additionally, the seat cushion 640 can have a thin layer of foam or other material, which is positioned between the cushion 640 and the trim cover 632 to provide additional cushioning for one or more areas of the seat component. Additionally, the seat assembly 620 may have a heating pad or heating mat positioned between the cushion 640 and the trim cover 632. By removing some or all of the conventional foam from the seat cushion 640, the seat assembly 620 may provide improved support and comfort, as well as reduced weight.

[0296] In one non-limiting example, the non-foam component or member 642 of the seat pad 640 is formed from a twisted mesh material (also referred to as an entangled three-dimensional filament structure). The twisted mesh material is made of a polymer mesh having a plurality of integrated polymer strands. The twisted mesh material can be made of, for example, a linear low density polyethylene (LLDPE) material, but other polymers and materials that are effective in providing the desired properties and functions are also contemplated. The twisted mesh material can be formed using extruded filaments of linear low density polyethylene (LLDPE) that are randomly entangled, bent, looped, or otherwise positioned and oriented, and directly bonded to each other to provide a porous mesh structure, an example of which is shown in Fig.29 Shown in a close-up view.

[0297] refer to Fig.28 , Fig.33 and Fig.37 , member 642 according to various embodiments is shown. Member 642 may be used as a cushion for a seat assembly (such as vehicle seat assembly 620), or in other non-vehicle or non-seat applications. Member 642 of cushion 640 may be formed as a single, one-piece component from a twisted mesh material, such as from a single extrusion as described below, and may be formed only from a twisted mesh material. In addition, the twisted mesh material may include a polymer mesh having a plurality of integrated polymer strands as described above.

[0298] The member 642 defines a first end region 650 and a second end region 652, wherein the first end region 650 and the second end region 652 are bounded by the outer perimeter of the member. In various examples, the first end region 650 is shaped to define or provide a seat back cushion region 630, and the second end region 652 is shaped to define or provide a seat bottom cushion region 628.

[0299] The member 642 further defines a first surface 654 for supporting an occupant on the cushion and a second surface 656 opposite the first surface and spaced apart from the first surface. The first surface 654 extends across the first end region 650 and the second end region 652, and the second surface 656 extends across the first end region 650 and the second end region 652. The first surface 654 is positioned on the seat assembly 620 to support an occupant of the seat assembly. The side surface 658 can extend around the perimeter of the member 642 and extend between the first surface 654 and the second surface 656.

[0300] Component 642 Fig.32 and Fig.36 is shown in a first position, and in Fig.28 , Fig.33 and Fig.37 is shown in the second use position. Fig.28 , Fig.33 and Fig.37 , member 642 has a first end region 650 positioned at a non-zero angle θ relative to a second end region 652. In one non-limiting example and as Fig.33 and Fig.37 As shown, the non-zero angle θ can be in the range of 90 degrees to 120 degrees, and in addition, can be in the range of 90 degrees to 150 degrees. In other examples, other non-zero angle ranges can also be envisioned. In the first position, the member 642 is provided in the shape when extruded, and in addition, the first end region 650 and the second end region 652 can be oriented at an angle of zero or substantially zero degrees relative to each other. As used herein, substantially means within the range of five degrees, ten degrees or fifteen degrees of the orientation. The member 642 can be bent, folded, bent or otherwise oriented from the first position to the second position, as further described below.

[0301] According to the example, component 642 is formed from Fig.32 shaped, bent, folded or folded to a first position as shown in Fig.33 As shown, the transition region 660 can be disposed between the first end region and the second end region.

[0302] According to another example, the member 642 may be formed or provided with one or more channels 662, which provide a relief for forming, bending, bending or folding the member 642 from a first position to a second position. In the example shown, one or more channels 662 are oriented to extend laterally across the member 642. The channel 662 may extend across the entire member 642 or only a portion thereof. In the example shown, the channel 662 intersects with the first surface 654 of the member 642 and is provided as an open channel that does not intersect with the second surface 656. In other examples, the channel may additionally or alternatively intersect with the second surface 656 and / or the side surface 658. The channel 662 may be positioned between the first end region 650 and the second end region 652 of the member 642, such as positioned in the transition region 660, to provide a relief for bending or forming the member 642 from a first position to a second position.

[0303] In one example, each channel 662 has a first face 664 and a second face 672, and when the member is in the first position, the channel 662 can be formed into a V-shape, a U-shape, or other cross-sectional shape. According to one non-limiting example, a V-shaped channel 662 is shown. When the member 642 is in the first position, the channel 662 can be formed into a V-shape, a U-shape, or other cross-sectional shape. Fig.37 In the second position shown, the first surface 664 and the second surface 672 mate with each other, contact each other, or are otherwise moved toward each other.

[0304] The first side 664 and the second side 672 may be connected to each other to hold the member 642 in place. Fig.37 The second position shown. In one example, one or more channel fasteners 668 are provided to connect the first face 664 to the second face 672 and to hold the member 642 in the second position. The channel fasteners 668 can be provided by a clamp ring, a hook and loop fastener, a barb fastener, a clip, etc. In another example, the first face 664 and the second face 672 can be additionally or alternatively bonded to each other, such as via an adhesive, or via a lamination or welding process by melting the strands on one face to the strands on the other face.

[0305] In other examples, other channels may additionally or alternatively be formed or disposed in the member 642 and extend in various directions, and further may be positioned to intersect the second surface 656, the side surface 658, or multiple surfaces.

[0306] In various examples, the cushion 640 also includes one or more auxiliary members 648 supported by the member 642, such as Fig.28 and Fig.34As shown. These auxiliary members 648 can be provided by separate extrusions of a stranded mesh material, other non-foam materials, foams such as molded polyurethane foam, or combinations thereof. The auxiliary members 648 can extend outwardly from the first surface 654 and / or the second surface 656 of the member 642, and can extend outwardly from the first end region 650 and / or the second end region 652. In one example, the auxiliary members 648 can form an element of the cushion 640, such as a side bolster or a lumbar cushion or a bolster.

[0307] The auxiliary member 648 can be connected to the member 642 to form the cushion 640. In one example, one or more auxiliary fasteners 670 are provided to connect the auxiliary member 648 to the member 642. The auxiliary fastener 670 can be provided by a clamp ring, a hook and loop fastener, a barb fastener, a clip, etc. In another example, the auxiliary member 648 can be additionally or alternatively bonded to the member 642, such as via an adhesive, or via a lamination or welding process by melting the strands on one side to the strands on the other side.

[0308] Although only relative to Fig.28 and Fig.34 Auxiliary member 648 is shown, but it is also contemplated that the auxiliary member may be attached to Fig.37 642 or otherwise by Fig.37 The member 642 supports.

[0309] Fig.30 A manufacturing process 700 for forming a stranded mesh material member, such as member 642 for cushion 640, is shown in accordance with an embodiment.

[0310] The hopper 710 contains raw material to be extruded, such as solid particles or pellets of the material. The material can be provided by plastic, such as linear low-density polyethylene (LLDPE). The material 14 is supplied from the hopper 710 to the extruder 720.

[0311] The extruder 720 melts the material and delivers it to the die plate 730. In one non-limiting example, the extruder 720 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction generated when the screw rotates. The material leaves the extruder 720 under pressure and in a molten state.

[0312] The die plate 730 extrudes the material into a filament 740. The die plate 730 may be arranged as described below according to the direction of the extrudate relative to the final component 642 produced therefrom. More specifically, the die plate 730 has a plurality of small circular through holes or orifices through which the molten material passes. A single filament 740 is extruded from each die plate hole. The filament 740 falls downward from the die plate to a funnel 750 under the action of system pressure and gravity, as described below. The funnel 750 may have a cross-sectional shape that is the same as or different from the shape defined by the orifices in the die plate.

[0313] Funnel 750 helps to consolidate or group filaments 740 into a more compact arrangement, in which filaments 740 are bent or looped, and each filament 740 contacts and is bonded to at least one other filament 740. Funnel 750 has a funnel inlet and a funnel outlet smaller than the funnel inlet. Funnel 750 is narrower at the funnel outlet than at the funnel inlet. Individual separated filaments 740 enter the funnel inlet, and when these filaments gather and slide downward toward the funnel outlet along funnel 750, filaments 740 are bent / looped and moved into contact with each other, and the consolidated filament structure 760 leaves the funnel outlet and immediately enters the water tank. In various examples, the filament structure can slide downward along the angled surface of funnel 750, thereby producing a material skin for structure 760, which is formed by two to three rows of filaments adjacent to the periphery of structure 760.

[0314] The liquid tank 770 contains water 772 or other fluid and receives the consolidated silk structure 760 from the funnel 750. The liquid 772 in the tank (bath) 770 helps to temporarily support the consolidated silk structure 760 to prevent the silk structure from collapsing or condensing into a less open or less porous arrangement and maintain the desired porosity and density. Therefore, the liquid 772 provides some resistance, which causes additional bending and looping of the silk 740 to further build the consolidated silk structure 760. Secondly, the liquid 772 cools the silk 740 from the outside to solidify the silk 740 and prevent the silk 740 from bonding at other locations.

[0315] The box 770 includes various rollers and conveyors, such as a pull conveyor 780, that help move the consolidated wire structure 760 through and out of the liquid 772. The roller and conveyor speeds may be controlled to move the consolidated wire structure 760 away from the hopper 750 at a speed related to the speed at which the consolidated wire structure 760 exits the hopper 750.

[0316] Other rollers, such as roller 782, help keep the consolidated filament structure 760 submerged in the liquid 772 and guide the consolidated filament structure 760 through the liquid 772 toward a conveyor belt 790 and a shaking table 792 disposed outside the box 770. While the consolidated filament structure 760 is on the conveyor belt 790, the shaking table 792 shakes the consolidated filament structure 760 to remove the liquid 772. Additionally or alternatively, pressurized air may be blown toward the consolidated filament structure 760, and / or the consolidated filament structure 760 may be squeezed to remove the liquid 772.

[0317] The consolidated wire structure 760 can then be cut into the desired size and shape. Fig.31 , the cut across the consolidated wire structure 760 forms the first surface 654 or the second surface 656 of the member 642. In another example, and for example Fig.35 The die 730 or funnel 750 shown in FIG. 7 forms the side surface 658 of the member 642 through the cut of the consolidated wire structure.

[0318] Optionally, the member 642 may be further machined or cut to form channels, passages, or shapes in the member 642 .

[0319] Fig.31 Shown for use with Fig.30 A top view of a tool 800 (such as a mold 730 and / or a funnel 750 ) used in conjunction with the manufacturing process 700 and in accordance with an embodiment. Fig.32 is shown in a first configuration or position and by Fig.31 The tool 800 provides a schematic side view of the twisted mesh material member 642. Note that Fig.28 A perspective view of the resulting member 642 according to one non-limiting example and in the second position can be seen in FIG.

[0320] In one example, Fig.31 A top view of tool 800 is shown as a mold 730 into which the wire flows downward. The apertures are arranged in a pattern as shown within a bounded perimeter 802 to form a first end region 650 and a second end region 652 of a component, such as a seat back cushion region and a seat base cushion region. The funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the pattern formed by the mold apertures.

[0321] For the resulting consolidated wire structure 760, the structure is cut so that the cut forms the first surface 654 or the second surface 656 as described above, and the member 642 retains the outer perimeter shape as shown by the mold and / or funnel pattern / perimeter 802. In addition, when, for example, passing through the reference Fig.31When the consolidated wire structure 760 is cut from the page, the side surface 658 of the resulting member 642 is formed by the extruded consolidated wire structure 760. Therefore, the thickness of the member 642 or the length of the side surface 658 is determined by the cutting position of the consolidated wire structure 760.

[0322] Fig.35 Shown for use with Fig.30 A top view of a tool 820 (such as a mold 730 and / or a funnel 750 ) used in conjunction with the manufacturing process 700 and in accordance with another embodiment. Fig.36 is shown in a first configuration or position and by Fig.31 A schematic side view of a twisted mesh material member 642 is provided by tool 820. Note that Fig.28 A perspective view of the resulting member 642 according to one non-limiting example and in the second position can be seen in FIG.

[0323] In one example, Fig.35 A top view of tool 820 is shown as a mold 820 with the wire flowing downward into template 730. The apertures are arranged in a pattern as shown within bounded perimeter 822 to form a first end region 650 and a second end region 652 of the component (e.g., a seat back cushion region and a seat base cushion region), as well as a channel through region 824. Funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the pattern formed by the mold apertures and channel 62. Funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the perimeter 822 formed by the mold apertures. In other examples, only funnel 750 forms region 824 to provide a channel in the wire structure, and mold 730 does not have this structure.

[0324] For the resulting consolidated wire structure 760, the structure is cut so that the cut forms the side surface 658 as described above, and the member 642 maintains the cross-sectional shape as shown by the mold pattern and / or funnel shape 822. In addition, when the consolidated wire structure 760, for example, passes through the reference Fig.35 When the sheet of the die 760 is cut, the first surface 654 and the second surface 656 of the resulting member 642 are formed by the extruded consolidated wire structure, for example, by the edges 826, 828 of the die 730. Therefore, the width of the member 642 or the distance between the opposing side surfaces 658 on the left and right sides of the member 642 is determined by the cutting position of the consolidated wire structure 760.

[0325] In another example, the die 730 and the funnel 750 can be shaped to extrude longitudinally (e.g., from top to bottom) and can include a region 824 to form a channel that extends longitudinally along the member rather than extending transversely as described above. In this example, the first surface 654 and the second surface 656 of the resulting member 642 are formed by the extruded consolidated wire structure 760. Therefore, the length of the member 642 or the distance between the top of the member 642 adjacent to the headrest and the opposite bottom of the member 642 is determined by the cutting position of the consolidated wire structure and the formation position of the side surfaces of the top and bottom of the member 642.

[0326] A method is provided and may be used to form member 642, assemble cushion 640, and assemble seat assembly 220. 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.

[0327] Component 642 uses a twisted mesh material such as described above. Fig.30 The stranded web material may be formed by extruding the material through a die 730 to form a first end region 650 and a second end region 652 of the member, discharging the extruded material from the die through a hopper 750, and moving the extruded material through one or more rollers 680, 682 after discharge.

[0328] Furthermore, one or more channels 662 may be formed during at least one of extruding the material, discharging the extruded material, and moving the extruded material. Alternatively, channels 662 may be formed in member 642 after consolidated wire structure 760 is cut to form the member.

[0329] The extruded material or consolidated wire structure 760 is cut to form at least one outer surface of the component. The outer surface can extend across the first end region 650 and the second end region 652, and can be the first surface 654, the second surface 656, or the side surface 658. When the component 642 is cut from the consolidated wire structure 760, the component 642 is in a state such as Fig.32 and Fig.36 The first position is shown. The member 642 may also be machined or otherwise processed to form other features, such as channels or passageways for connecting trim components or for locating or receiving various components or systems of the seat assembly.

[0330] The first end region 650 of the twisted mesh material member 642 is oriented at a non-zero angle relative to the second end region 652 of the member to move the member from the first position to the position as shown in FIG. Fig.33 and Fig.37In one example, the twisted mesh material member 642 is bent or curved from the first position to the second position to orient the member. The channel 662, if provided, can provide a relief portion or location for the bend or curve.

[0331] The first end region 650 is held at a non-zero angle relative to the second end region 652, and wherein the member 642 is in the second position. In various examples, one or more channel fasteners 668 are inserted into the opposed sides or faces 664, 672 of the channel, the opposed sides 664, 672 of the channel are joined together, or a combination of both are used to hold the first end region 650 relative to the second end region 652 in the second position.

[0332] One or more auxiliary members 648 are formed. The auxiliary member 648 can be composed of the above Fig.30 The process description and Fig.29 642 . The auxiliary member 648 is formed of a twisted mesh material similar to the twisted mesh material shown in , and is formed separately from the member 642. Alternatively, the auxiliary member 648 can be formed as other non-foam members or foam members. The auxiliary member 648 is attached to the member 642. When the member 642 is in the first position and / or the second position, the auxiliary member 648 can be attached to the member 642. The auxiliary member 648 can also be attached to the first surface 654, the second surface 656 and / or the side surface 658 of the member 642. In various examples, one or more auxiliary fasteners 670 are inserted into the auxiliary member 648 and the member 642, the auxiliary member 648 is combined with the member 642, or a combination of the two is used to hold the auxiliary member 648 to the member 642.

[0333] The member 642 is attached to the frame 622 of the seat assembly to provide the frame of the seat assembly with a cushion 640. The trim cover 632 can be positioned over the member 642 and the cushion 640. The trim cover 632 can be connected to the cushion 640 and / or the frame 622.

[0334] Various embodiments provide a single extrusion of member 642 to create the overall area for cushion 640, including seat back 626 and seat bottom 624. By further including channels 662 and / or auxiliary members 648, the desired shape of cushion 640 is provided while maintaining the ease of a single extrusion.

[0335] Seat assembly, seat or chair may be used herein to generally refer to an assembly incorporating the teachings of one or more embodiments disclosed herein, which assembly may include any combination of embodiments disclosed herein or features of embodiments. Similarly, the terms: seat assembly, seat or chair may refer to the same or similar components. Seat bottom, backrest, substrate, headrest, head cushion or bolster may be used herein to generally refer to any component, area or portion of a seat assembly, vehicle seat or chair. A layer, sheet, substrate, portion, region, area or segment may refer to any planar, non-planar, shaped or contoured portion or area of ​​a seat bottom, backrest, substrate, headrest, head cushion or bolster formed from any disclosed material or combination of materials to provide comfort and / or structure to the seat bottom, backrest, substrate, headrest, head cushion or bolster. Bond, connect, weld, sew, fasten, retain, adhere, attach, couple, or rivet may refer to any manufacturing method or process for connecting parts, with or without fasteners, retainers, adhesives, welds, clamp rings, connector strips, retaining clips, hook and loop fasteners, clamps, deflected angled ribbed shank fasteners, barb fasteners, laminates, compression molded parts, or additional decorative parts. Wire, strand, bend, or loop may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh structure) after being dispensed through one or more apertures of a die, plate, template, tool, tool plate, extrusion die, or cutout plate, or other variations thereof, and they are also used to refer to equivalent parts. Similarly, the terms: consolidated filament structure, filament structure, entangled filament structure, yield strand, main body, net, final member, non-foam component, non-woven net, non-foam material, support, component, core, component, extruded material, cushion, pad or pad component can refer to the same or similar components. The terms funnel and cover can also be used to refer to the same or similar components. The description herein can also use various terms to refer to holes, such as holes, pores, nozzles, orifices, etc. In another example, boxes, water tanks, cooling chambers, liquid boxes and tanks can refer to the same or similar components. When describing different preferred embodiments, different terms can be used to refer to the same or similar components to avoid confusion. These terms can be interchangeable because various components from the features of various embodiments can be combined in a manner not explicitly described herein. This does not detract from the fact that some terms can provide inherent details that other interchangeable terms do not include, unless otherwise explicitly stated (for example, water tanks and fluid tanks refer to similar interchangeable components, but in at least one preferred embodiment, the box is filled with water or arranged to be filled with water when the water tank is used, rather than any liquid).

[0336] A cushion (e.g., 640) is described, which can be a seat bottom cushion, a seat back cushion, a headrest, a head cushion, a bolster, a region, a portion. The cushion (e.g., 640) includes a member (e.g., 642), which can be foam, non-foam, and / or a combination thereof. The member (e.g., 642) includes a twisted mesh material, which can be a polymer mesh with multiple integrated polymer strands, a tangled three-dimensional filament structure, a linear low-density polyethylene, an extruded filament, which is randomly tangled, bent, looped, or otherwise positioned and oriented, and / or directly bonded to each other to provide a porous mesh structure. The member (e.g., 642) defines a first end region (e.g., 650) and a second end region (e.g., 652), the first end region can be shaped to define a seat back cushion, and the second end region can be shaped to define a seat base cushion. The first end region (e.g., 650) and the second end region (e.g., 652) are defined by the outer periphery of the member (e.g., 642). The first end region (eg, 650) is positioned (bent, folded, bent, and / or oriented) at a non-zero angle (such as 90-120 degrees, or 90-150 degrees) relative to the second end region (eg, 652).

[0337] In some embodiments, a member (eg, 642) is formed solely of a twisted mesh material.

[0338] In some embodiments, the stranded mesh material comprises a polymer mesh having a plurality of integrated polymer strands.

[0339] In some embodiments, the first end region (eg, 650 ) is shaped to define a seat back pad; and wherein the second end region (eg, 652 ) is shaped to define a seat base pad.

[0340] In some embodiments, the member (e.g., 642) also includes a first surface for supporting an occupant on the cushion (e.g., 640) and a second surface opposite the first surface, the first surface extending across a first end region (e.g., 650) and a second end region (e.g., 652), and the second surface extending across the first end region and the second end region.

[0341] In some embodiments, the member (e.g., 642) defines one or more channels, which may be V-shaped, U-shaped and / or provide a pressure relief portion for forming, bending, folding, or folding, each channel intersecting one of the first surface and the second surface, each channel may extend laterally, and / or intersect the side surface.

[0342] In some embodiments, the channel extends transversely across the member (eg, 642) and is positioned between a first end region (eg, 650) and a second end region (eg, 652).

[0343] In some embodiments, the channel includes a first side and a second side, wherein the first side and the second side mate with each other.

[0344] In some embodiments, the liner (e.g., 640) further includes one or more channel fasteners (e.g., 668) that connect the first side to the second side to maintain the first end region (e.g., 650) at a non-zero angle relative to the second end region (e.g., 652).

[0345] In some embodiments, one or more auxiliary members (e.g., 648) such as bolsters or lumbar pads are supported by the member (e.g., 642).

[0346] In some embodiments, the auxiliary member (eg, 648) comprises a twisted mesh material.

[0347] In some embodiments, the auxiliary member (e.g., 648) extends outward from at least one of the first end region (e.g., 650) and the second end region (e.g., 652) of the member (e.g., 642).

[0348] In some embodiments, the pad (e.g., 640) also includes one or more auxiliary member (e.g., 648) fasteners, which may be pliers, hook and loop fasteners, barb fasteners, clips, adhesives, laminates, and / or welds that connect the auxiliary member (e.g., 648) to the member (e.g., 642).

[0349] In some embodiments, auxiliary members (eg, 648) are shaped and positioned on members (eg, 642) to form side bolsters or lumbar pads.

[0350] A seat assembly is described, which may be a vehicle seat, an office chair, and / or a personal chair. The seat assembly includes a frame, which may be a stamped steel alloy, a fiber reinforced polymer, and / or any suitable structural material, a wire suspension pad, a substrate, and / or sheet stock, and a cushion (e.g., 640) according to any of the foregoing or subsequent techniques. The cushion (e.g., 640) is supported by the frame.

[0351] A tool is described. The tool includes: a die (e.g., 730) (or a funnel) defining a series of apertures arranged to extrude material of a twisted mesh material member for a cushion (e.g., 640) according to any of the preceding or subsequent techniques. The series of apertures are arranged to define an outer perimeter of a member (e.g., 642) containing a seat back region and a seat base region.

[0352] In some embodiments, the series of apertures are also arranged such that the outer perimeter defines one or more channels for a member (eg, 642).

[0353] In some embodiments, the series of apertures are arranged such that one or more channels are positioned between the seat back region and the seat base region.

[0354] Fig.38 A method 3800 is shown according to some embodiments. The method 3800 is used to position (such as bend, fold, bend and / or orient) a twisted mesh material member, which can be a polymer mesh having multiple integrated polymer strands, an entangled three-dimensional filament structure, a linear low-density polyethylene, an extruded filament that is randomly entangled, bent, looped or otherwise positioned and oriented, and / or directly bonded to each other to provide a porous mesh structure. In various examples, the method 3800 can have more or fewer steps than described below, and the various steps can be performed in another order, sequentially, or simultaneously.

[0355] Method 3800 includes: positioning (3802) (such as bending, folding, curving and / or orienting) a first end region (e.g., 650) of a member (642) at a non-zero angle (e.g., 90 degrees-120 degrees and / or 90 degrees-150 degrees) relative to a second end region (e.g., 652) of a twisted mesh material member (e.g., 642), the first end region can be formed to define a seat back pad, the twisted mesh material member can be a polymer mesh having multiple integrated polymer strands, a tangled three-dimensional filament structure, a linear low density polyethylene, extruded filaments that are randomly tangled, bent, looped or otherwise positioned and oriented and / or directly bonded to each other to provide a porous mesh structure; and maintaining (3804) the first end region (e.g., 650) at a non-zero angle relative to the second end region (e.g., 652) with or without hooks and loops, hook and loop fasteners, barb fasteners, clips, adhesives, laminates and / or welds.

[0356] In some embodiments, method 3800 includes forming a stranded mesh material member (eg, 642) by extruding the material through a die.

[0357] In some embodiments, a stranded mesh material member (eg, 642) is extruded to form a first end region (eg, 650) and a second end region (eg, 652).

[0358] In some embodiments, forming the stranded mesh material member (eg, 642) further comprises discharging the extruded material from the die through a funnel.

[0359] In some embodiments, method 3800 includes moving the extruded material through one or more rollers after expulsion.

[0360] In some embodiments, method 3800 includes forming (which may be by means of extrusion, die cutting, robotic laser cutting, water jet cutting, laser cutting and / or other flexible automation) one or more channels during at least one of extruding material, discharging the extruded material, and moving the extruded material.

[0361] In some embodiments, method 3800 includes cutting (which may be accomplished by die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automation) one or more channels in a component (eg, 642).

[0362] In some embodiments, method 3800 includes inserting one or more fasteners (such as pliers, hook and loop fasteners, barb fasteners, clips, adhesives, laminates, and / or welds) into opposite sides of the channel and / or joining opposite sides of the channel to hold a first end region (e.g., 650) relative to a second end region (e.g., 652).

[0363] In some embodiments, method 3800 includes cutting (which can be accomplished by die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automation) the extruded material to form an outer surface of a member (e.g., 642) that extends across a first end region (e.g., 650) and a second end region (e.g., 652).

[0364] In some embodiments, method 3800 includes bending a twisted mesh material member (eg, 642) from a first position to a second position to orient the member (eg, 642).

[0365] In some embodiments, method 3800 includes attaching (using pliers, hook and loop fasteners, barb fasteners, clips, adhesives, laminates, and / or welds) one or more auxiliary components (e.g., 648) to a component (e.g., 642).

[0366] In some embodiments, method 3800 includes forming an auxiliary member (eg, 648) from a stranded mesh material, such as by extrusion.

[0367] In some embodiments, attaching the auxiliary member (e.g., 648) to the member (e.g., 642) also includes inserting one or more fasteners (which may be pliers, hook and loop fasteners, barb fasteners, clips, adhesives, laminates, and / or welds) into the auxiliary member (e.g., 648) and the member (e.g., 642), and / or coupling the auxiliary member (e.g., 648) to the member (e.g., 642).

[0368] In some embodiments, method 3800 also includes attaching a member (e.g., 642) to a frame of the seat assembly (e.g., a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material, wire suspension pad, substrate, and / or sheet stock) to provide padding (e.g., 640) for the frame.

[0369] The above techniques may optionally be combined with one or more elements of the above methods. For example, these parts may be used in combination with another method 400, 1600, 1650, 1680, 2700.

[0370] Clause 1. A seat support, in combination or without any of the subsequent clauses, comprising a plurality of planar layers for mounting to a seat frame and supporting an occupant on the seat frame, wherein the plurality of planar layers are stacked upon one another and each of the plurality of stacked layers has a varying density.

[0371] Clause 2. A seat support according to any preceding or subsequent clause, wherein the density of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0372] Clause 3. A seat support as recited in any preceding or subsequent clause, wherein the firmness of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0373] Clause 4. A seat support according to any preceding or subsequent clause, wherein a plurality of stacked layers are connected together.

[0374] Clause 5. A seat support according to any preceding or subsequent clause, wherein each sequential pair of the plurality of stacked layers are bonded together.

[0375] Clause 6. A seat support according to any preceding or subsequent clause, wherein each sequential pair of the plurality of stacked layers are welded, stitched, fastened or adhered together.

[0376] Clause 7. A seat support according to any preceding or subsequent clause, wherein the plurality of stacked layers further comprises rubber, thick carpet, needle punched cotton fabric, polyethylene terephthalate or polypropylene.

[0377] Clause 8. The seat support of any preceding or subsequent clause, wherein the plurality of stacked layers further comprises a base layer adapted to be mounted to a seat frame, wherein the base layer is formed of a denser material than other layers in the plurality of stacked layers.

[0378] Clause 9. A seat support according to any preceding or subsequent clause, wherein the base layer is formed from an elastomeric material.

[0379] Clause 10. A seat support according to any preceding or subsequent clause, wherein the base layer is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

[0380] Clause 11. A seat support according to any preceding or subsequent clause, wherein the base layer has a thickness of two millimeters or less.

[0381] Clause 12. A seat assembly comprising: a base plate adapted to be mounted to a seat frame; and a seat support according to any preceding or subsequent clause, the seat support stacked on the base plate.

[0382] Clause 13. The seat assembly of any preceding or subsequent clause, wherein the substrate is formed of an elastomeric material.

[0383] Clause 14. The seat assembly of any preceding or subsequent clause, wherein the substrate is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride.

[0384] Clause 15. The seat assembly of any preceding or subsequent clause, further comprising a seat frame, wherein the substrate is attached to the seat frame.

[0385] Clause 16. A seat support, in combination or without any of the preceding or subsequent clauses, comprising a plurality of flat layers for mounting to a seat frame and supporting an occupant on the seat frame, wherein the plurality of flat layers are stacked upon one another, and wherein the density of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0386] Clause 17. A method for manufacturing a seat assembly, in combination or without any of the preceding or subsequent clauses, the method comprising: unfolding a first sheet of a first material; cutting a first seat support layer from the first sheet; mounting the first seat support layer on a substrate; unfolding a second sheet of a second material, the second material having a density less than that of the first material; cutting a second seat support layer from the second sheet; and mounting the second seat support layer on the first seat support layer.

[0387] Clause 18. The method of any preceding or subsequent clause further comprising: unfolding a third sheet of a third material having a density less than that of the second material; cutting a third seat support layer from the third sheet; and installing the third seat support layer on the second seat support layer.

[0388] Clause 19. The method of any preceding or subsequent clause, further comprising bonding a second seat support layer to the first seat support layer.

[0389] Clause 20. A seat assembly manufactured by the method according to any preceding or subsequent clause.

[0390] Clause 21. A seat support, in combination or without any preceding or subsequent clause, comprising a plurality of layers of an extruded thermoplastic resin web for mounting to a seat frame and supporting an occupant on the seat frame, wherein the plurality of layers are stacked upon one another.

[0391] Clause 22. The seat support of any preceding or subsequent clause, wherein at least one of the plurality of stacked layers has a substantially uniform thickness.

[0392] Clause 23. The seat support of any preceding or subsequent clause, wherein each of the plurality of stacked layers has a substantially uniform thickness.

[0393] Clause 24. The seat support of any preceding or subsequent clause, wherein the seat support further comprises at least two stacked layers.

[0394] Clause 25. A seat support as recited in any preceding or subsequent clause, wherein each of the plurality of stacked layers are pivotally connected to one another.

[0395] Clause 26. A seat support according to any preceding or subsequent clause, wherein at least one recess is formed into one of the plurality of stacked layers to provide a pivot connection.

[0396] Clause 27. The seat support of any preceding or subsequent clause, wherein each of the plurality of stacked layers is integrally formed.

[0397] Clause 28. A seat assembly comprising: a seat frame; and a seat support according to any preceding or subsequent clause, the seat support attached to the seat frame.

[0398] Clause 29. A seat support, in combination or without any of the preceding or subsequent clauses, comprising a plurality of layers for mounting to a seat frame and supporting an occupant on the seat frame, wherein the plurality of layers are stacked upon one another; wherein at least one of the plurality of stacked layers has a substantially uniform thickness; wherein each of the plurality of stacked layers is integrally formed; and wherein each of the plurality of stacked layers is pivotally connected to one another.

[0399] Clause 30. A method of making a product, in combination with or without any preceding or subsequent clause, the method comprising: forming a plurality of cushion segments from an extruded thermoplastic resin web; and stacking the plurality of cushion segments into a cushion.

[0400] Clause 31. The method of any preceding or subsequent clause, further comprising shaping a plurality of gasket segments.

[0401] Clause 32. The method of any preceding or subsequent clause, further comprising forming the plurality of gasket segments into a unitary sheet.

[0402] Clause 33. The method of any preceding or subsequent clause, further comprising folding the cushion segments so that the cushion segments are stacked on top of each other.

[0403] Clause 34. The method of any preceding or subsequent clause, further comprising forming at least one recess in at least one of the plurality of gasket segments to fold the gasket segment.

[0404] Clause 35. The method of any preceding or subsequent clause, further comprising cutting the plurality of gasket segments to shape the plurality of gasket segments.

[0405] Clause 36. A seat support manufactured according to any preceding or subsequent clause.

[0406] Clause 37. The method of any preceding or subsequent clause, further comprising mounting the product to a seat frame.

[0407] Clause 38. A seat assembly manufactured by the method according to any preceding or subsequent clause.

[0408] Clause 39. A method for designing a seat cushion, in combination with or without any preceding or subsequent clause, the method comprising: obtaining a design of a unitary seat cushion; and redesigning the unitary seat cushion design into a plurality of stacked cushion segment designs.

[0409] Clause 40. The method of any preceding or subsequent clause, further comprising redesigning the unitary seat cushion design into a plurality of stacked cushion segment designs each having a common maximum thickness.

[0410] Clause 41. A method of manufacturing a seat cushion, the method comprising: designing a plurality of seat cushion segments according to any preceding or subsequent clause; and forming the plurality of cushion segments from an extruded thermoplastic resin web.

[0411] Clause 42. The method of any preceding or subsequent clause, further comprising stacking a plurality of liner segments as a liner.

[0412] Clause 43. A vehicle seat cushion component, in combination or without any of the preceding or subsequent clauses, the vehicle seat cushion component comprising: a first plastic mesh cushion pillow comprising a first plurality of three-dimensional wire loops formed from a first thermoplastic polymer; a second plastic mesh cushion pillow comprising a second plurality of three-dimensional wire loops formed from a second thermoplastic polymer; and a plastic mesh base comprising a third plurality of three-dimensional wire loops formed from a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first side, and a second side, wherein the first plastic mesh cushion pillow is attached to the plastic mesh base at the first edge, and the second plastic mesh cushion pillow is attached to the plastic mesh base at the first edge.

[0413] Clause 44. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

[0414] Clause 45. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the first plurality of three-dimensional wire loops, the second plurality of three-dimensional wire loops, and the third plurality of three-dimensional wire loops each independently include a plurality of fused connections in which two loops are attached to one another.

[0415] Clause 46. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plurality of three-dimensional wire loops and the second plurality of three-dimensional wire loops are each independently shaped into a form for a vehicle seat bolster.

[0416] Clause 47. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plastic mesh bolster and the second plastic mesh bolster are each disposed over the first face.

[0417] Clause 48. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plastic mesh bolster is attached to the first edge and the second plastic mesh bolster is attached to the second edge.

[0418] Clause 49. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plastic mesh bolster and the second plastic mesh bolster are attached to the plastic mesh substrate by hook and loop strips, adhesive, retaining clips, and / or clamp rings.

[0419] Clause 50. A vehicle seat cushion component according to any preceding or subsequent clause, wherein at least a subset of the loops in the first plurality of three-dimensional wire loops, at least a subset of the loops in the second plurality of three-dimensional wire loops, and at least a subset of the loops in the third plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0420] Clause 51. A vehicle seat cushion component according to any preceding or subsequent clause, wherein at least a subset of the loops in the first plurality of three-dimensional wire loops, at least a subset of the loops in the second plurality of three-dimensional wire loops, and at least a subset of the loops in the third plurality of three-dimensional wire loops are randomly oriented.

[0421] Clause 52. The vehicle seat cushion component of any preceding or subsequent clause, the first skin layer disposed on the first side of the plastic mesh substrate.

[0422] Clause 53. The vehicle seat cushion component of any preceding or subsequent clause, the first skin layer disposed on the second side of the plastic mesh substrate.

[0423] Clause 54. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plastic mesh bolster, the first plastic mesh bolster, and the plastic mesh substrate independently comprise 60% to 95% air by volume.

[0424] Clause 55. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plastic mesh pillow, the first plastic mesh pillow, and the plastic mesh substrate independently have a g / cm 3 Up to 0.200g / cm 3 density.

[0425] Clause 56. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extruded thermoplastic polymer.

[0426] Clause 57. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer each independently comprise a component selected from the group consisting of: a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, and a polyamide-based thermoplastic elastomer.

[0427] Clause 58. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently a linear low density polyethylene.

[0428] Clause 59. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first plurality of three-dimensional wire loops, the second plurality of three-dimensional wire loops, and the third plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0429] Clause 60. A vehicle seat cushion component, in combination with or without any of the preceding or subsequent clauses, the vehicle seat cushion component comprising: a first plastic mesh cushion pillow comprising a first plurality of three-dimensional wire loops formed from a first thermoplastic polymer; a second plastic mesh cushion pillow comprising a second plurality of three-dimensional wire loops formed from a second thermoplastic polymer; and a plastic mesh base comprising a third plurality of three-dimensional wire loops formed from a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first side, and a second side, wherein the first plastic mesh cushion pillow is attached to the plastic mesh base at the first edge, and the second plastic mesh cushion pillow is attached to the plastic mesh base at the first edge, wherein the first plurality of three-dimensional wire loops, the second plurality of three-dimensional wire loops, and the third plurality of three-dimensional wire loops each independently comprise a plurality of fused connections in which two loops are attached to each other.

[0430] Clause 61. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

[0431] Clause 62. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the plastic mesh substrate is 60% to 95% air by volume.

[0432] Clause 63. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer each independently comprise a component selected from the group consisting of: polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0433] Clause 64. A vehicle seat cushion component, in combination or without any of the preceding or subsequent clauses, comprising: a first bolster assembly comprising a first core cushion portion surrounded by a first outer bolster cover, the first outer bolster cover being surrounded by a first bolster decorative cover; a second bolster assembly comprising a second core cushion portion surrounded by a second outer bolster cover; and a decorative cover portion having a first edge and a second edge, the first bolster assembly being sewn to the decorative cover portion at the first edge, and the second bolster assembly being sewn to the decorative cover portion at the second edge.

[0434] Clause 65. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

[0435] Clause 66. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first bolster assembly and the second bolster assembly are each independently formed by compression molding.

[0436] Clause 67. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first outer bolster cover and the second outer bolster cover each independently comprise a nonwoven fabric.

[0437] Clause 68. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first outer bolster cover and the second outer bolster cover each independently comprise natural fibers.

[0438] Clause 69. The vehicle seat cushion component of any preceding or subsequent clause, further comprising a central cushion component positioned in an opening defined by the trim cover portion.

[0439] Clause 70. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently constructed of foamed polyurethane.

[0440] Clause 71. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the first core cushion portion, the second core cushion portion, and the central cushion portion are each independently constructed from a plurality of three-dimensional wire loops constructed from a thermoplastic polymer.

[0441] Clause 72. The vehicle seat cushion component of any preceding or subsequent clause, wherein the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to one another.

[0442] Clause 73. The vehicle seat cushion component of any preceding or subsequent clause, wherein at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0443] Clause 74. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first core cushion portion, the second core cushion portion, and the central cushion component independently have 60% to 95% air by volume.

[0444] Clause 75. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first core cushion portion, the second core cushion portion, and the central cushion portion each independently have a relative humidity of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

[0445] Clause 76. The vehicle seat cushion component of any preceding or subsequent clause, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0446] Clause 77. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0447] Clause 78. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the thermoplastic polymer is a biodegradable or recyclable polymer.

[0448] Clause 79. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0449] Clause 80. A vehicle seat cushion component according to any preceding or subsequent clause, further comprising providing sound insulation and temperature buffering.

[0450] Clause 81. A vehicle seat, in combination or without any of the preceding or subsequent clauses, the vehicle seat comprising: a seat bottom having a seat bottom frame; a seat back attached to the seat bottom, the seat back comprising a seat back frame; and a vehicle seat cushion component attached to the seat bottom frame and / or the seat back frame, the vehicle seat cushion component comprising: a first cushion assembly comprising a first core cushion portion surrounded by a first outer cushion cover, the first outer cushion cover being surrounded by a first cushion decorative cover; a second cushion assembly comprising a second core cushion portion surrounded by a second outer cushion cover, the second outer cushion cover being surrounded by a second cushion decorative cover; and a decorative cover portion having a first edge and a second edge, the first cushion assembly being sewn to the decorative cover portion at the first edge, and the second cushion assembly being sewn to the decorative cover portion at the second edge.

[0451] Clause 82. The vehicle seat of any preceding or subsequent clause, wherein the first outer bolster cover and the second outer bolster cover each independently comprise a non-woven fabric.

[0452] Clause 83. The vehicle seat of any preceding or subsequent clause, wherein the first outer bolster covering and the second outer bolster covering each independently comprise natural fibers.

[0453] Clause 84. The vehicle seat of any preceding or subsequent clause, wherein the vehicle seat cushion component further comprises a central cushion component positioned in the opening defined by the trim cover portion.

[0454] Clause 85. The vehicle seat of any preceding or subsequent clause, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently constructed of foamed polyurethane.

[0455] Clause 86. The vehicle seat of any preceding or subsequent clause, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently constructed from a plurality of three-dimensional wire loops constructed from a thermoplastic polymer.

[0456] Clause 87. The vehicle seat of any preceding or subsequent clause, wherein the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to one another.

[0457] Clause 88. The vehicle seat of any preceding or subsequent clause, wherein at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0458] Clause 89. The vehicle seat of any preceding or subsequent clause, wherein the first core cushion portion and the second core cushion portion are 60% to 95% air by volume.

[0459] Clause 90. The vehicle seat of any preceding or subsequent clause, wherein the first core cushion portion and the second core cushion portion each independently have a thickness of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

[0460] Clause 91. The vehicle seat of any preceding or subsequent clause, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0461] Clause 92. A vehicle seat cushion component, in combination or without any of the preceding or subsequent clauses, the vehicle seat cushion component comprising: a plastic mesh base, the plastic mesh base comprising a plurality of three-dimensional wire loops, the three-dimensional wire loops being composed of a thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first side, and a second side; a first foam cushion attached to the plastic mesh base at the first edge; and a second foam cushion attached to the plastic mesh base at the second edge.

[0462] Clause 93. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

[0463] Clause 94. The vehicle seat cushion component of any preceding or subsequent clause, wherein the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to one another.

[0464] Clause 95. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first foam bolster and the second foam bolster are each independently comprised of a foamed polymer.

[0465] Clause 96. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first foam bolster and the second foam bolster are each independently constructed of foamed polyurethane.

[0466] Clause 97. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first foam bolster and the second foam bolster are each at least partially disposed over the first face.

[0467] Clause 98. The vehicle seat cushion component of any preceding or subsequent clause, wherein the first foam bolster is attached to the first edge and the second foam bolster is attached to the second edge.

[0468] Clause 99. A vehicle seat cushion component according to any of the preceding or subsequent clauses, wherein the first foam bolster is attached to a plastic mesh base using a first retaining clip, and the first foam bolster is attached to the plastic mesh base using a second retaining clip, the first retaining clip and the second retaining clip each having an end that is embedded in the foam of the first foam bolster or the second foam bolster, respectively, and a retaining clip end that is attached to the plastic mesh base.

[0469] Clause 100. The vehicle seat cushion component of any preceding or subsequent clause, wherein at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

[0470] Clause 101. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the loops in the plurality of three-dimensional wire loops are randomly oriented.

[0471] Clause 102. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the plastic mesh substrate is 60% to 95% air by volume.

[0472] Clause 103. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the plastic mesh substrate has a g / cm 3 Up to 0.200g / cm 3 density.

[0473] Clause 104. The vehicle seat cushion component of any preceding or subsequent clause, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0474] Clause 105. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the thermoplastic polymer comprises a component selected from the group consisting of: polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0475] Clause 106. The vehicle seat cushion component of any preceding or subsequent clause, wherein the thermoplastic polymer comprises linear low density polyethylene.

[0476] Clause 107. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0477] Clause 108. A vehicle seat cushion component, in combination or in absence of any preceding or subsequent clause, comprising: a plastic mesh substrate comprising a plurality of three-dimensional wire loops composed of a thermoplastic polymer.

[0478] Clause 109. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

[0479] Clause 110. The vehicle seat cushion component of any preceding or subsequent clause, wherein the plurality of three-dimensional wire loops comprises a plurality of fused connections where two loops are attached to one another.

[0480] Clause 111. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the loops in the plurality of three-dimensional wire loops are randomly oriented.

[0481] Clause 112. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the plastic mesh substrate is 60% to 95% air by volume.

[0482] Clause 113. A vehicle seat cushion component according to any preceding or subsequent clause, wherein the thermoplastic polymer comprises a component selected from the group consisting of: polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0483] Clause 114. An assembly, in combination or without any of the preceding or subsequent clauses, comprising: at least one fabric sized to be displaced over a surface of a cushion; and at least one retainer coupled to the at least one fabric along a periphery of the fabric to receive a decorative component, an actuator, a heat transfer layer, or any combination thereof.

[0484] Clause 115. An assembly according to any preceding or subsequent clause, further comprising a gasket.

[0485] Clause 116. An assembly according to any preceding or subsequent clause, wherein the cushion further comprises a stranded mesh material.

[0486] Clause 117. The assembly of any preceding or subsequent clause, further comprising a trim cover sized to at least partially surround the cushion and the at least one fabric, wherein the trim cover is coupled to the at least one retainer.

[0487] Clause 118. The assembly of any preceding or subsequent clause, wherein at least one retainer comprises at least one clamping ring.

[0488] Clause 119. The assembly of any preceding or subsequent clause, wherein at least one retainer is not directly coupled to the pad.

[0489] Clause 120. The assembly of any preceding or subsequent clause, wherein at least one fabric further comprises a nonwoven material.

[0490] Clause 121. An assembly according to any preceding or subsequent clause, wherein the nonwoven material further comprises jute.

[0491] Clause 122. A seat assembly comprising: a seat bottom; a seat back; and a seat trim assembly according to any preceding or subsequent clause, the seat trim assembly being located in the seat bottom or the seat back.

[0492] Item 123. A product formed by a method with or without any of the preceding or subsequent items, the method comprising: connecting at least one retainer to the periphery of at least one fabric; stacking at least one fabric on a pad; and connecting a decorative component, an actuator, a heat transfer layer, or any combination thereof, to at least one retainer.

[0493] Clause 124. A product formed by the method of any preceding or subsequent clause, the method further comprising compression molding at least one fabric to the contour of the cushion prior to stacking the at least one fabric on the cushion.

[0494] Clause 125. A product formed by the method of any preceding or subsequent clause, the method further comprising coupling a trim cover sized to at least partially surround the cushion and the at least one fabric to the at least one retainer.

[0495] Clause 126. The product of any preceding or subsequent clause, wherein stacking at least one fabric on a pad further comprises stacking at least one fabric on a twisted mesh material pad.

[0496] Clause 127. A product formed by the method of any preceding or subsequent clause, the method further comprising not directly coupling at least one retainer to the liner.

[0497] Clause 128. A product formed by the method of any preceding or subsequent clause, further comprising clamping at least one clamping ring to the fabric as at least one retainer.

[0498] Clause 129. A seat assembly comprising: a seat bottom; a seat back; and a product according to any preceding or subsequent clause located in the seat bottom or the seat back.

[0499] Clause 130. A method, in combination or without any of the preceding or subsequent clauses, comprising: coupling at least one retainer to a periphery of at least one fabric; stacking at least one fabric on a cushion; and coupling a decorative component, an actuator, a heat transfer layer, or any combination thereof, to at least one retainer.

[0500] Clause 131. The method of any preceding or subsequent clause, further comprising at least partially enclosing the cushion and the at least one fabric by coupling a trim cover to the at least one retainer.

[0501] Clause 132. The method of any preceding or subsequent clause, wherein at least one fabric further comprises a nonwoven material.

[0502] Clause 133. A trim component manufactured by a method according to any preceding or subsequent clause.

[0503] Clause 134. A pad, in combination or without any of the preceding or subsequent clauses, comprising: a member comprising a twisted mesh material, the member defining a first end region and a second end region, the first end region and the second end region being bounded by an outer periphery of the member; and wherein the first end region is positioned at a non-zero angle relative to the second end region.

[0504] Clause 135. A pad according to any preceding or subsequent clause, wherein the member is formed solely of a stranded mesh material.

[0505] Clause 136. The pad of any preceding or subsequent clause, wherein the twisted mesh material comprises a polymer mesh having a plurality of integrated polymer strands.

[0506] Clause 137. The cushion of any preceding or subsequent clause, wherein the first end region is shaped to define a seat back cushion; and wherein the second end region is shaped to define a seat base cushion.

[0507] Clause 138. A cushion according to any preceding or subsequent clause, wherein the member further comprises a first surface for supporting an occupant on the cushion and a second surface opposite the first surface, the first surface extending across a first end region and a second end region, and the second surface extending across the first end region and the second end region.

[0508] Clause 139. The cushion of any preceding or subsequent clause, wherein the member defines one or more channels, each channel intersecting one of the first surface and the second surface.

[0509] Clause 140. The liner of any preceding or subsequent clause, wherein the channel extends transversely across the member and is positioned between the first end region and the second end region.

[0510] Clause 141. The liner of any preceding or subsequent clause, wherein the channel comprises a first side and a second side, wherein the first side and the second side cooperate with each other.

[0511] Clause 142. The gasket of any preceding or subsequent clause, further comprising one or more channel fasteners connecting the first face to the second face to hold the first end region at a non-zero angle relative to the second end region.

[0512] Clause 143. A cushion according to any preceding or subsequent clause, further comprising one or more auxiliary members supported by the member.

[0513] Clause 144. A pad according to any preceding or subsequent clause, wherein the auxiliary member comprises a twisted mesh material.

[0514] Clause 145. A cushion according to any preceding or subsequent clause, wherein the auxiliary member extends outwardly from at least one of the first end region and the second end region of the member.

[0515] Clause 146. A gasket according to any preceding or subsequent clause, further comprising one or more auxiliary member fasteners connecting the auxiliary member to the member.

[0516] Clause 147. A cushion according to any preceding or subsequent clause, wherein the auxiliary member is shaped and positioned on the member to form a side bolster or lumbar cushion.

[0517] Clause 148. A seat assembly comprising: a frame; and a cushion according to any preceding or subsequent clause, the cushion being supported by the frame.

[0518] Clause 149. A tool comprising: a die defining a series of orifices arranged to extrude material for a twisted mesh material member for padding according to any preceding or subsequent clause, the series of orifices arranged to define an outer periphery of the member, the outer periphery including a seat back area and a seat base area.

[0519] Clause 150. The tool of any preceding or subsequent clause, wherein the series of apertures are further arranged such that the outer perimeter defines one or more channels for a component.

[0520] Clause 151. A tool as set forth in any preceding or subsequent clause, wherein the series of apertures are arranged such that one or more channels are positioned between a seat back region and a seat base region.

[0521] Clause 152. A method, in combination or without any preceding or subsequent clause, comprising: positioning a first end region of a twisted mesh material member at a non-zero angle relative to a second end region of the member; and maintaining the first end region at a non-zero angle relative to the second end region.

[0522] Clause 153. The method of any preceding or subsequent clause, further comprising forming the stranded mesh material member via extruding the material through a die.

[0523] Clause 154. The method of any preceding or subsequent clause, wherein the stranded web material member is extruded to form the first end region and the second end region.

[0524] Clause 155. The method of any preceding or subsequent clause, wherein forming the stranded web material member further comprises discharging the extruded material from the die through a hopper.

[0525] Clause 156. The method of any preceding or subsequent clause, further comprising moving the extruded material through one or more rollers after discharge.

[0526] Clause 157. The method of any preceding or subsequent clause, further comprising forming one or more channels during at least one of extruding the material, discharging the extruded material, and moving the extruded material.

[0527] Clause 158. The method of any preceding or subsequent clause, further comprising cutting one or more channels in the component.

[0528] Clause 159. The method of any preceding or subsequent clause, further comprising inserting one or more fasteners into and / or engaging opposite sides of the channel to retain the first end region relative to the second end region.

[0529] Clause 160. The method of any preceding or subsequent clause, further comprising cutting the extruded material to form an outer surface of the member, the outer surface extending across the first end region and the second end region.

[0530] Clause 161. The method of any preceding or subsequent clause, further comprising bending the twisted mesh material member from a first position to a second position to orient the member.

[0531] Clause 162. The method of any preceding or subsequent clause, further comprising attaching one or more auxiliary components to the component.

[0532] Clause 163. The method of any preceding or subsequent clause, further comprising forming an auxiliary member from a twisted mesh material.

[0533] Clause 164. The method of any preceding or subsequent clause, wherein attaching the auxiliary component to the component further comprises inserting one or more fasteners into the auxiliary component and the component and / or bonding the auxiliary component to the component.

[0534] Clause 165. The method of any preceding or subsequent clause, further comprising attaching a member to a frame of a seat assembly to provide padding for the frame of the seat assembly.

[0535] Clause 166. Any combination of any of the preceding clauses 1-165.

[0536] Although various embodiments are described above, this does not mean that these embodiments describe all possible forms according to the present disclosure. In this regard, the words used in this specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. In addition, the features of various implementation embodiments can be combined to form additional embodiments according to the present disclosure.

Claims

1. A seat support, comprising: a) a plurality of planar layers for mounting to a seat frame and supporting an occupant on the seat frame, wherein the plurality of planar layers are stacked upon one another and each of the plurality of stacked layers has a varying density; b) multiple layers or regions of plastic mesh, wherein the multiple layers are stacked, attached or positioned at a non-zero angle relative to each other; c) a first bolster assembly, a second bolster assembly, and a trim cover portion, the first bolster assembly comprising a first core cushion portion surrounded by a first outer bolster cover, the first outer bolster cover being surrounded by the first bolster trim cover, the second bolster assembly comprising a second core cushion portion surrounded by a second outer bolster cover, the trim cover portion having a first edge and a second edge, the first bolster assembly being sewn to the trim cover portion at the first edge, and the second bolster assembly being sewn to the trim cover portion at the second edge; d) a plastic mesh substrate comprising a plurality of three-dimensional wire loops comprised of a thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first side, and a second side, a first foam bolster attached to the plastic mesh substrate at the first edge, and a second foam bolster attached to the plastic mesh substrate at the second edge; and / or e) at least one fabric sized to be displaced over a surface of the cushion and at least one retainer coupled to the at least one fabric along a perimeter of the fabric to receive a decorative component, an actuator, a heat transfer layer, or any combination thereof.

2. The seat support according to claim 1 further includes the plurality of flat layers for mounting to the seat frame and supporting an occupant on the seat frame, wherein the plurality of flat layers are stacked on each other and each of the plurality of stacked layers has a varying density.

3. The seat support according to claim 1 or 2, wherein: The density of the plurality of stacked layers varies in a sequentially increasing manner from the occupant supporting surface to the base layer.

4. A seat support according to any one of the preceding claims, wherein: The firmness of the plurality of stacked layers varies in a sequentially increasing manner from the occupant supporting surface to the base layer.

5. A seat support according to any one of the preceding claims, wherein: The plurality of stacked layers are connected together.

6. A seat support according to any one of the preceding claims, wherein: Each sequential pair of the plurality of stacked layers is bonded together.

7. A seat support according to any one of the preceding claims, wherein: Each sequential pair of the plurality of stacked layers is welded, sewn, fastened or adhered together.

8. A seat support according to any one of the preceding claims, wherein: The plurality of stacked layers may also include rubber, thick carpet, needle punched cotton, polyethylene terephthalate or polypropylene.

9. A seat support according to any one of the preceding claims, wherein: The plurality of stacked layers also includes a base layer adapted to be mounted to the seat frame, wherein the base layer is formed of a denser material than other layers in the plurality of stacked layers.

10. The seat support according to claim 9, wherein: The base layer is formed of an elastomeric material.

11. A seat support according to claim 9 or 10, wherein: The base layer is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

12. The seat support according to claim 11, wherein: The base layer has a thickness of two millimeters or less.

13. A seat support according to any one of the preceding claims, further comprising the plurality of flat layers, and the plurality of flat layers are used to support an occupant on the seat frame, wherein the plurality of flat layers are stacked on top of each other, and wherein the density of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

14. A seat support according to any one of the preceding claims, further comprising said plurality of layers of said plastic mesh, and said plurality of layers of said plastic mesh being used to support an occupant on said seat frame, wherein said plurality of layers are stacked upon one another; and The plastic mesh further comprises an extruded thermoplastic resin mesh.

15. A seat support according to any one of the preceding claims, wherein: At least one of the plurality of stacked layers has a substantially uniform thickness.

16. A seat support according to any one of the preceding claims, wherein: Each of the plurality of stacked layers has a substantially uniform thickness.

17. A seat support according to any one of the preceding claims, wherein: The seat support also includes at least two stacked layers.

18. A seat support according to any one of the preceding claims, wherein: Each of the plurality of stacked layers are pivotally connected to each other.

19. The seat support of claim 18, wherein: At least one recess is formed into one of the plurality of stacked layers to provide a pivot connection.

20. A seat support according to claim 18 or 19, wherein: Each of the plurality of stacked layers is integrally formed.

21. A seat support according to any one of the preceding claims, further comprising said plurality of layers for mounting to a seat frame and for supporting an occupant on said seat frame, wherein said plurality of layers are stacked upon one another; wherein at least one of the plurality of stacked layers has a substantially uniform thickness; wherein each of the plurality of stacked layers is integrally formed; and Wherein each of the plurality of stacked layers are pivotally connected to each other.

22. The seat support of claim 1, wherein: The plurality of layers of the plastic mesh further comprises: a first plastic mesh pillow comprising a first plurality of three-dimensional wire loops formed from a first thermoplastic polymer; a second plastic mesh pillow comprising a second plurality of three-dimensional wire loops comprised of a second thermoplastic polymer; and A plastic mesh substrate comprising a third plurality of three-dimensional wire loops comprised of a third thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first side, and a second side, wherein the first plastic mesh cushion is attached to the plastic mesh substrate at the first edge, and the second plastic mesh cushion is attached to the plastic mesh substrate at the first edge.

23. A seat support according to any preceding claim, wherein: The vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

24. A seat support according to any one of claims 22 or 23, wherein The first plurality of three-dimensional wire loops, the second plurality of three-dimensional wire loops, and the third plurality of three-dimensional wire loops each independently include a plurality of fused connections in which two loops are attached to each other.

25. A seat support according to any one of claims 22 to 24, wherein The first plurality of three-dimensional wire loops and the second plurality of three-dimensional wire loops are each independently shaped into a form for a vehicle seat bolster.

26. A seat support according to any one of claims 22 to 25, wherein The first plastic mesh pillow and the second plastic mesh pillow are each disposed above the first surface.

27. A seat support according to any one of claims 22 to 26, wherein The first plastic mesh pillow is attached to the first edge and the second plastic mesh pillow is attached to the second edge.

28. A seat support according to any one of claims 22 to 29, wherein The first plastic mesh cushion pillow and the second plastic mesh cushion pillow are attached to the plastic mesh substrate by hook and loop strips, adhesives, retaining clips and / or clamp rings.

29. A seat support according to any one of claims 22 to 30, wherein: At least a subset of the loops in the first plurality of three-dimensional wire loops, at least a subset of the loops in the second plurality of three-dimensional wire loops, and at least a subset of the loops in the third plurality of three-dimensional wire loops are not parallel or aligned with each other.

30. A seat support according to any one of claims 22 to 31, wherein: At least a subset of the loops in the first plurality of three-dimensional wire loops, at least a subset of the loops in the second plurality of three-dimensional wire loops, and at least a subset of the loops in the third plurality of three-dimensional wire loops are randomly oriented.

31. A seat support as claimed in any one of claims 22 to 32, further comprising a first skin layer disposed on the first side of the plastic mesh substrate.

32. A seat support as claimed in any one of claims 22 to 33 further comprising a first skin layer disposed on the second side of the plastic mesh substrate.

33. A seat support according to any one of claims 22 to 34, wherein: The first plastic mesh cushion pillow, the first plastic mesh cushion pillow, and the plastic mesh base independently comprise 60% to 95% air by volume.

34. A seat support according to any one of claims 22 to 35, wherein: The first plastic mesh pillow, the first plastic mesh pillow and the plastic mesh substrate independently have a thickness of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

35. A seat support according to any one of claims 22 to 36, wherein The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extrusion thermoplastic polymer.

36. A seat support according to any one of claims 22 to 37, wherein The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer each independently include a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

37. A seat support according to any one of claims 22 to 38, wherein The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently a linear low density polyethylene.

38. A seat support according to any one of claims 22 to 39, wherein The first plurality of three-dimensional wire loops, the second plurality of three-dimensional wire loops, and the third plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

39. The seat support of claim 1, wherein: The plurality of layers of the plastic mesh further comprises: a first plastic mesh pillow comprising a first plurality of three-dimensional wire loops formed from a first thermoplastic polymer; a second plastic mesh pillow comprising a second plurality of three-dimensional wire loops comprised of a second thermoplastic polymer; and A plastic mesh substrate, the plastic mesh substrate comprising a third plurality of three-dimensional wire loops formed from a third thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first face, and a second face, wherein the first plastic mesh cushion is attached to the plastic mesh substrate at the first edge, and the second plastic mesh cushion is attached to the plastic mesh substrate at the first edge, wherein the first plurality of three-dimensional wire loops, the second plurality of three-dimensional wire loops, and the third plurality of three-dimensional wire loops each independently comprise a plurality of fused connections in which two loops are attached to each other.

40. A seat support according to any preceding claim, wherein: The vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

41. A seat support according to any one of claims 22 to 42, wherein: The plastic mesh substrate has 60% to 95% air by volume.

42. A seat support according to any one of claims 22 to 43, wherein: The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer each independently include a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

43. The seat support of claim 1 further comprising: the first bolster assembly comprising the first core cushion portion surrounded by the first outer bolster cover, the first outer bolster cover being surrounded by the first bolster trim cover; the second bolster assembly comprising the second core cushion portion surrounded by the second outer bolster cover; and The trim cover portion has the first edge and the second edge, the first bolster assembly is sewn to the trim cover portion at the first edge, and the second bolster assembly is sewn to the trim cover portion at the second edge.

44. A seat support according to any preceding claim, wherein: The vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

45. A seat support according to any one of claims 45 to 46, wherein The first bolster assembly and the second bolster assembly are each independently formed by compression molding.

46. ​​A seat support according to any one of claims 45 to 47, wherein The first outer bolster cover and the second outer bolster cover each independently include a nonwoven fabric.

47. A seat support according to any one of claims 45 to 48, wherein The first outer bolster cover and the second outer bolster cover each independently include natural fibers.

48. A seat support as claimed in any one of claims 45 to 49 further comprising a central pad component positioned in an opening defined by the trim cover portion.

49. A seat support according to any one of claims 45 to 50, wherein The first core cushion portion, the second core cushion portion and the central cushion component are each independently composed of foamed polyurethane.

50. A seat support according to any one of claims 45 to 51, wherein The first core cushion portion, the second core cushion portion, and the central cushion component are each independently constructed from a plurality of three-dimensional wire loops constructed from a thermoplastic polymer.

51. A seat support according to any one of claims 45 to 52, wherein The plurality of three-dimensional wire loops include a plurality of fused connections where two loops are attached to each other.

52. A seat support according to any one of claims 45 to 53, wherein: At least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

53. A seat support according to any one of claims 45 to 54, wherein: The first core cushion portion, the second core cushion portion and the central cushion component independently have 60% to 95% air by volume.

54. A seat support according to any one of claims 45 to 55, wherein The first core cushion portion, the second core cushion portion, and the central cushion component each independently have a relative humidity of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

55. A seat support according to any one of claims 45 to 56, wherein The thermoplastic polymer is an extruded thermoplastic polymer.

56. A seat support according to any one of claims 45 to 57, wherein The thermoplastic polymer includes a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

57. A seat support according to any one of claims 45 to 58, wherein The thermoplastic polymer is a biodegradable or recyclable polymer.

58. A seat support according to any one of claims 45 to 59, wherein The plurality of three-dimensional wire loops have a fineness of 200 dtex to 10000 dtex.

59. A seat support as claimed in any one of claims 45 to 60 further comprising providing sound insulation and temperature buffering.

60. The seat support of claim 1 further comprising a vehicle seat cushion component, the vehicle seat cushion component comprising: The plastic mesh substrate, the plastic mesh substrate comprising a plurality of three-dimensional wire loops, the three-dimensional wire loops being composed of the thermoplastic polymer, the plastic mesh substrate having the first edge, the second edge, the first face and the second face; the first foam bolster, the first foam bolster being attached to the plastic mesh base at the first edge; and The second foam bolster is attached to the plastic mesh base at the second edge.

61. A seat support according to claim 62, wherein: The vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

62. A seat support according to any one of claims 62 to 63, wherein: The plurality of three-dimensional wire loops include a plurality of fused connections where two loops are attached to each other.

63. A seat support according to any one of claims 62 to 64, wherein The first foam bolster and the second foam bolster are each independently comprised of a foamed polymer.

64. A seat support according to any one of claims 62 to 65, wherein The first foam bolster and the second foam bolster are each independently formed of foamed polyurethane.

65. A seat support according to any one of claims 62 to 66, wherein The first foam bolster and the second foam bolster are each at least partially disposed over the first face.

66. A seat support according to any one of claims 62 to 67, wherein The first foam bolster is attached to the first edge and the second foam bolster is attached to the second edge.

67. A seat support according to any one of claims 62 to 68, wherein The first foam bolster is attached to the plastic mesh base using a first retaining clip, and the first foam bolster is attached to the plastic mesh base using a second retaining clip, the first retaining clip and the second retaining clip each having an end embedded in the foam of the corresponding first foam bolster or the second foam bolster, and a retaining clip end attached to the plastic mesh base.

68. A seat support according to any one of claims 62 to 69, wherein At least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

69. A seat support according to any one of claims 62 to 70, wherein The loops in the plurality of three-dimensional wire loops are randomly oriented.

70. A seat support according to any one of claims 62 to 71, wherein The plastic mesh substrate has 60% to 95% air by volume.

71. A seat support according to any one of claims 62 to 72, wherein: The plastic mesh substrate has a thickness of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

72. A seat support according to any one of claims 62 to 73, wherein The thermoplastic polymer is an extruded thermoplastic polymer.

73. A seat support according to any one of claims 62 to 74, wherein: The thermoplastic polymer includes a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

74. A seat support according to any one of claims 62 to 75, wherein The thermoplastic polymer includes linear low density polyethylene.

75. A seat support according to any one of claims 62 to 76, wherein The plurality of three-dimensional wire loops have a fineness of 200 dtex to 10000 dtex.

76. The seat support of claim 1 further comprising a vehicle seat cushion component, the vehicle seat cushion component comprising: The plastic mesh substrate comprises a plurality of three-dimensional wire loops, and the three-dimensional wire loops are made of thermoplastic polymer.

77. A seat support according to claim 78, wherein: The vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

78. A seat support according to any one of claims 78 to 79, wherein The plurality of three-dimensional wire loops include a plurality of fused connections where two loops are attached to each other.

79. A seat support according to any one of claims 78 to 80, wherein The loops in the plurality of three-dimensional wire loops are randomly oriented.

80. A seat support according to any one of claims 78 to 81, wherein The plastic mesh substrate has 60% to 95% air by volume.

81. A seat support according to any one of claims 78 to 82, wherein The thermoplastic polymer includes a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

82. The seat support of claim 1, further comprising an assembly, the assembly further comprising: the at least one fabric sized to be displaced on the surface of the pad; and The at least one retainer is coupled to the at least one fabric along the perimeter of the fabric to receive the trim component, the actuator, the heat transfer layer, or any combination thereof.

83. The seat support of claim 84 further comprising said pad.

84. A seat support according to claim 85, wherein: The liner also includes a stranded mesh material.

85. The seat support of claim 85 or 86, further comprising a trim cover sized to at least partially surround the cushion and the at least one fabric, wherein the trim cover is coupled to the at least one retainer.

86. A seat support as claimed in claims 84 to 87, wherein: The at least one retainer includes at least one clamping ring.

87. A seat support as claimed in claims 84 to 88, wherein: The at least one retainer is not directly coupled to the gasket.

88. A seat support as claimed in claims 84 to 89, wherein: The at least one fabric further comprises a nonwoven material.

89. The seat support of claim 80, wherein: The nonwoven material also includes jute.

90. The seat support of claim 1 further comprising: a member comprising a stranded mesh material as the plastic mesh, the member defining a first end region and a second end region, the first end region and the second end region being bounded by an outer perimeter of the member; and Wherein the first end region is positioned at a non-zero angle relative to the second end region.

91. A seat support according to claim 92, wherein: The member is formed solely from the stranded mesh material.

92. A seat support according to claim 93, wherein: The stranded mesh material includes a polymer mesh having a plurality of integrated polymer strands.

93. A seat support according to any one of claims 92 to 94, wherein: The first end region is shaped to define a seat back pad; and Wherein the second end region is shaped to define a seat base pad.

94. A seat support according to any one of claims 92 to 95, wherein: The member also includes a first surface for supporting an occupant on the pad and a second surface opposite the first surface, the first surface extending across the first end region and the second end region, and the second surface extending across the first end region and the second end region.

95. A seat support according to claim 96, wherein: The member defines one or more channels, each channel intersecting one of the first surface and the second surface.

96. A seat support according to claim 97, wherein: The channel extends transversely across the member and is positioned between the first end region and the second end region.

97. A seat support according to any one of claims 97 to 98, wherein The channel includes a first face and a second face, wherein the first face and the second face cooperate with each other.

98. The seat support of claim 99 further comprising one or more channel fasteners connecting the first face to the second face to maintain the first end region at the non-zero angle relative to the second end region.

99. A seat support as claimed in any one of claims 92 to 100 further comprising one or more auxiliary members supported by the member.

100. The seat support of claim 101, wherein: The auxiliary member comprises a twisted mesh material.

101. A seat support according to any one of claims 101 to 102, wherein: The auxiliary member extends outwardly from at least one of the first end region and the second end region of the member.

102. A seat support as claimed in any one of claims 101 to 103 further comprising one or more auxiliary member fasteners connecting the auxiliary member to the member.

103. A seat support according to any one of claims 101 to 104, wherein: The auxiliary member is shaped and positioned on the member to form a side bolster or a lumbar pad.

104. A seat assembly comprising: a base plate adapted to be mounted to a seat frame; and A seat support as claimed in any preceding claim stacked on the base plate.

105. The seat assembly of claim 106, wherein: The substrate is formed of an elastomeric material.

106. The seat assembly of claim 106 or 107, wherein: The substrate is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

107. The seat assembly of any one of claims 106 to 108, further comprising a seat frame, wherein the substrate is attached to the seat frame.

108. A seat assembly comprising: Seat frame; and A seat support as claimed in any one of claims 1 to 105, attached to or supported by the seat frame.

109. A seat assembly comprising: Seat bottom; Seat backs; and 106. A seat support as claimed in any one of claims 1 to 105 located in the seat bottom or the seat back.

110. A vehicle seat, comprising: a seat bottom having a seat bottom frame; a seat back attached to the seat bottom, the seat back comprising a seat back frame; and A seat support according to any one of claims 1 and 45 to 61, wherein the seat support further comprises a vehicle seat cushion component attached to the seat bottom frame and / or the seat back frame, the vehicle seat cushion component comprising: the first bolster assembly including the first core cushion portion surrounded by the first outer bolster cover, the first outer bolster cover being surrounded by the first bolster trim cover; the second bolster assembly including the second core cushion portion surrounded by the second outer bolster cover, the second outer bolster cover surrounded by the second bolster trim cover; and The trim cover portion has the first edge and the second edge, the first bolster assembly being sewn to the trim cover portion at the first edge, and the second bolster assembly being sewn to the trim cover portion at the second edge.

111. The vehicle seat of claim 112, wherein: The first outer bolster cover and the second outer bolster cover each independently include a nonwoven fabric.

112. A vehicle seat according to any one of claims 112 to 113, wherein: The first outer bolster cover and the second outer bolster cover each independently include natural fibers.

113. A vehicle seat according to any one of claims 112 to 114, wherein: The vehicle seat cushion component also includes a center cushion component positioned in an opening defined by the trim cover portion.

114. A vehicle seat according to any one of claims 112 to 115, wherein: The first core cushion portion, the second core cushion portion and the central cushion component are each independently composed of foamed polyurethane.

115. A vehicle seat according to any one of claims 112 to 116, wherein: The first core cushion portion, the second core cushion portion, and the central cushion component are each independently constructed from a plurality of three-dimensional wire loops constructed from a thermoplastic polymer.

116. A vehicle seat according to any one of claims 112 to 117, wherein: The plurality of three-dimensional wire loops include a plurality of fused connections where two loops are attached to each other.

117. A vehicle seat according to any one of claims 112 to 118, wherein: At least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or aligned with each other.

118. A vehicle seat according to any one of claims 112 to 119, wherein: The first core cushion portion and the second core cushion portion have 60% to 95% air by volume.

119. A vehicle seat according to any one of claims 112 to 120, wherein: The first core cushion portion and the second core cushion portion each independently have a thickness of about 0.01 g / cm 3 Up to 0.200g / cm 3 density.

120. A vehicle seat according to any one of claims 112 to 121, wherein: The thermoplastic polymer is an extruded thermoplastic polymer.

121. A tool comprising: A die defining a series of orifices arranged to extrude material for the twisted mesh material component for the cushion according to any one of claims 92 to 105, the series of orifices arranged to define an outer periphery of the component, the outer periphery including a seat back area and a seat base area.

122. The tool of claim 123, wherein: The series of apertures are also arranged such that the outer periphery defines one or more channels for the member.

123. The tool of claim 124, wherein: The series of apertures are arranged such that the one or more channels are positioned between the seat back region and the seat base region.

124. A method of manufacturing a product, the method comprising: a) A first sub-method, wherein the first sub-method comprises: i) unfolding a first sheet of a first material, ii) cutting a first seat support layer from said first sheet, iii) mounting the first seat support layer on a substrate, iv) unfolding a second sheet of a second material, the second material having a density less than the first material, v) cutting a second seat support layer from said second sheet, and vi) installing the second seat support layer on the first seat support layer; b) A second sub-method, wherein the second sub-method comprises: i) forming a plurality of layers or regions of a plastic web, and ii) stacking or attaching the plurality of layers or regions relative to each other, or positioning the plurality of gasket segments at a non-zero angle relative to each other; c) A third sub-method, the third sub-method comprising: i) sewing a first bolster assembly to a first edge of the trim cover portion, the first bolster assembly having a first core cushion portion surrounded by a first outer bolster cover, the first outer bolster cover being surrounded by the first bolster trim cover, and ii) sewing a second bolster assembly to said second edge of said trim cover portion, said second bolster assembly having a second core cushion portion surrounded by a second outer bolster cover; d) A fourth sub-method, the fourth sub-method comprising: i) attaching a first foam pillow to a first edge of a plastic mesh substrate comprising a plurality of three-dimensional wire loops comprised of a thermoplastic polymer, and ii) attaching a second foam pillow to a second edge of the plastic mesh substrate; and / or e) A fifth sub-method, the fifth sub-method comprising: i) coupling at least one retainer to a periphery of at least one fabric, ii) stacking the at least one fabric on a pad, and iii) coupling a trim component, an actuator, a heat transfer layer, or any combination thereof to the at least one retainer.

125. The method of claim 126, further comprising the first sub-method.

126. The method of claim 126 or 127, further comprising: unfolding a third sheet of a third material, the third material having a density less than that of the second material; cutting a third seat support layer from the third sheet; and The third seat support layer is mounted on the second seat support layer.

127. The method of any one of claims 126 to 128, further comprising bonding the second seat support layer to the first seat support layer.

128. The method according to claim 126 also includes the second sub-method.

129. The method of any one of claims 126 and 130, further comprising shaping the plurality of liner segments.

130. The method of any one of claims 126, 130, and 131, further comprising forming the plurality of gasket segments into a unitary sheet.

131. The method of claim 132, further comprising folding the liner segments to stack the liner segments on top of each other.

132. The method of claim 133, further comprising forming at least one recess in at least one of the plurality of gasket segments to fold the gasket segment.

133. The method of any one of claims 126 and 130 to 134, further comprising cutting the plurality of liner segments to shape the plurality of liner segments.

134. The method according to claim 126 also includes the fifth sub-method.

135. The method of claim 136, further comprising at least partially enclosing the cushion and the at least one fabric by coupling a trim cover to the at least one retainer.

136. The method of claims 136 to 137, wherein: The at least one fabric further comprises a nonwoven material.

137. The method of claim 16, further comprising: positioning a first end region of the twisted mesh material member of the plurality of cushion segments at a non-zero angle relative to a second end region of the member; as well as The first end region is maintained at the non-zero angle relative to the second end region.

138. The method of claim 139, further comprising forming the twisted mesh material member by extruding material through a die.

139. The method of claim 140, wherein: The stranded web material member is extruded to form the first end region and the second end region.

140. The method according to any one of claims 140 to 141, wherein Forming the stranded web material member further includes discharging the extruded material from the die through a hopper.

141. The method of claim 142, further comprising moving the extruded material through one or more rollers after discharge.

142. The method of claim 143, further comprising forming one or more channels during at least one of extruding the material, discharging the extruded material, and moving the extruded material.

143. The method of any one of claims 140 to 144, further comprising cutting the one or more channels in the member.

144. The method of any one of claims 144 to 145, further comprising inserting one or more fasteners into opposite sides of the channel and / or coupling the opposite sides of the channel to hold the first end region relative to the second end region.

145. The method of any one of claims 140 to 146, further comprising cutting the extruded material to form an outer surface of the member, the outer surface extending across the first end region and the second end region.

146. The method of any one of claims 139 to 147, further comprising bending the twisted mesh material member from a first position to a second position to orient the member.

147. The method of any one of claims 139 to 148, further comprising attaching one or more auxiliary components to the component.

148. The method of claim 149, further comprising forming the auxiliary member from a twisted mesh material.

149. The method of any one of claims 149 to 150, wherein attaching the auxiliary member to the member further comprises inserting one or more fasteners into the auxiliary member and the member and / or bonding the auxiliary member to the member.

150. The method of any one of claims 139 to 151 further comprising attaching the member to a frame of a seat assembly to provide padding for the frame of the seat assembly.

151. A method for designing a seat pad, the method comprising: Get the one-piece seat pad design; and Redesigning a one-piece seat cushion design into multiple stacked, stitched or attached seat cushion segment designs.

152. The method of claim 153 further comprising redesigning the integral seat pad design into the plurality of stacked seat pad segment designs each having a common maximum thickness.

153. A method of manufacturing a seat pad, the method comprising: Designing a plurality of liner segments according to claim 153 or 154; as well as The plurality of gasket segments are formed from an extruded thermoplastic resin web.

154. The method of claim 155 further comprising stacking the plurality of liner segments into a liner.

155. A seat support manufactured by the method of any one of claims 139 to 152 or designed by the method of any one of claims 153 to 56.

156. The method of any one of claims 139 to 156, further comprising mounting the product to a seat frame.

157. A seat assembly manufactured by the method of claim 158.

158. The seat support of claim 157 manufactured by the method, further comprising: coupling the at least one retainer to a perimeter of the at least one fabric; stacking the at least one fabric on the pad; as well as The trim component, the actuator, the heat transfer layer, or any combination thereof are coupled to the at least one retainer.

159. A seat support manufactured by the method of claim 160, the method further comprising compression molding the at least one fabric to the contour of the cushion prior to stacking the at least one fabric on the cushion.

160. A seat support manufactured by the method as described in claims 160 to 161, the method further comprising coupling a trim cover to the at least one retainer, the trim cover being sized to at least partially surround the cushion and the at least one fabric.

161. A seat support manufactured by the method as claimed in claims 160 to 162, wherein: Stacking the at least one fabric on the pad also includes stacking the at least one fabric on a twisted mesh material pad.

162. A seat support manufactured by the method of claims 160 to 163, further comprising not directly coupling the at least one retainer to the cushion.

163. A seat support formed and manufactured by the method as claimed in claims 160 to 164, wherein: Also included is clamping at least one clamping ring to the fabric as the at least one retainer.

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