Seat support, seat assembly including seat support, tooling for extruding seat support material, and method for manufacturing seat support.

Abstract

The seat support component comprises multiple flat layers for mounting to the seat frame and supporting the occupant on the seat frame. The multiple flat layers are stacked on top of each other, and each of the stacked layers has a varying density. The seat support component also comprises one or more layers of extruded thermoplastic resin mesh for mounting to the seat frame and supporting the occupant on the seat frame. The multiple layers can be stacked on top of each other.

Description

Cross-reference to related applications

[0001] This application claims priority to the following applications: U.S. Application No. 63 / 351,902, filed June 14, 2022; U.S. Application No. 63 / 356,555, filed June 29, 2022; U.S. Application No. 63 / 355,754, filed June 27, 2022; U.S. Application No. 63 / 355,793, filed June 27, 2022; U.S. Application No. 63 / 355,700, filed June 27, 2022; U.S. Application No. 63 / 357,056, filed June 30, 2022; U.S. Application No. 63 / 355,158, filed June 24, 2022; and U.S. Application No. PA 2023, filed April 25, 2023. Danish application 70197; the contents of these applications are hereby incorporated herein by reference in their entirety. Technical Field

[0002] Various embodiments relate to vehicle seat components, seat cushions, seat assemblies, methods for manufacturing seat cushions, and methods for designing seat cushions.

[0003] This application relates to the following aspects:

[0004] 1. A seat support member, comprising:

[0005] a) 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 on top of each other and each of the plurality of stacked layers has a varying density;

[0006] b) Multiple layers or regions of a plastic mesh, wherein the multiple layers are stacked, attached or positioned relative to each other at a non-zero angle;

[0007] c) A first pillow assembly, a second pillow assembly, and a decorative cover portion, wherein the first pillow assembly includes a first core pad portion surrounded by a first outer pillow cover, the first outer pillow cover being surrounded by a first pillow decorative cover, the second pillow assembly includes a second core pad portion surrounded by a second outer pillow cover, the decorative cover portion having a first edge and a second edge, the first pillow assembly being sewn to the decorative cover portion at the first edge, and the second pillow assembly being sewn to the decorative cover portion at the second edge;

[0008] d) A plastic mesh substrate, a first foam pad, and a second foam pad, wherein the plastic mesh substrate comprises a plurality of three-dimensional loops made of a thermoplastic polymer, the plastic mesh substrate has a first edge, a second edge, a first surface, and a second surface, the first foam pad is attached to the plastic mesh substrate at the first edge, and the second foam pad is attached to the plastic mesh substrate at the second edge; and / or

[0009] e) at least one fabric and at least one retainer, the at least one fabric being sized to be displaced on the surface of the padding, the at least one retainer being attached to the at least one fabric along the periphery of the fabric to receive a decorative element, an actuator, a heat transfer layer or any combination thereof.

[0010] 2. The seat support according to aspect 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 top of each other, and each of the plurality of stacked layers has a varying density.

[0011] 3. The seat support according to aspect 1 or 2, wherein the density of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0012] 4. The seat support according to any one of the foregoing aspects, wherein the solidity of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0013] 5. The seat support according to any one of the foregoing aspects, wherein the plurality of stacked layers are connected together.

[0014] 6. The seat support according to any one of the foregoing aspects, wherein each sequential pair of the plurality of stacked layers is combined together.

[0015] 7. The seat support according to any one of the foregoing aspects, wherein each sequential pair of the plurality of stacked layers is welded, sewn, fastened or adhered together.

[0016] 8. The seat support according to any one of the foregoing aspects, wherein the plurality of stacked layers further comprises rubber, a thick blanket, needle-punched cotton fabric, polyethylene terephthalate, or polypropylene.

[0017] 9. The seat support according to any one of the preceding aspects, wherein the plurality of stacked layers further includes a base layer adapted for mounting to the seat frame, wherein the base layer is formed of a denser material than the other layers of the plurality of stacked layers.

[0018] 10. The seat support according to aspect 9, wherein the base layer is formed of an elastomeric material.

[0019] 11. The seat support according to aspect 9 or 10, wherein the base layer is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

[0020] 12. The seat support according to aspect 11, wherein the base layer has a thickness of two millimeters or less.

[0021] 13. The seat support according to any one of the foregoing aspects further includes 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.

[0022] 14. The seat support according to any one of the foregoing aspects, further comprising the plurality of layers of the plastic mesh, wherein the plurality of layers of the plastic mesh are used to support an occupant on the seat frame, wherein the plurality of layers are stacked on top of each other; and wherein the plastic mesh further comprises an extruded thermoplastic resin mesh.

[0023] 15. The seat support according to any one of the foregoing aspects, wherein at least one of the plurality of stacked layers has a substantially uniform thickness.

[0024] 16. The seat support according to any one of the foregoing aspects, wherein each of the plurality of stacked layers has a substantially uniform thickness.

[0025] 17. The seat support according to any one of the preceding aspects, wherein the seat support further comprises at least two stacked layers.

[0026] 18. The seat support according to any one of the foregoing aspects, wherein each of the plurality of stacked layers is pivotally connected to each other.

[0027] 19. The seat support according to aspect 18, wherein at least one recess is formed in one of the plurality of stacked layers to provide a pivot connection.

[0028] 20. The seat support according to aspect 18 or 19, wherein each of the plurality of stacked layers is integrally formed.

[0029] 21. The seat support according to any one of the preceding aspects, further comprising the plurality of layers for mounting to a seat frame and for supporting an occupant on the seat frame, wherein the plurality of layers are stacked on top of each other; 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 each other.

[0030] 22. The seat support according to aspect 1, wherein the plurality of layers of the plastic mesh further include:

[0031] A first plastic mesh pillow, the first plastic mesh pillow comprising a first plurality of three-dimensional filament loops made of a first thermoplastic polymer;

[0032] A second plastic mesh pillow, the second plastic mesh pillow comprising a second plurality of three-dimensional filament loops composed of a second thermoplastic polymer; and

[0033] A plastic mesh substrate comprising a third plurality of three-dimensional filament loops made of a third thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first surface, and a second surface, wherein a first plastic mesh pad is attached to the plastic mesh substrate at the first edge, and a second plastic mesh pad is attached to the plastic mesh substrate at the first edge.

[0034] 23. The seat support according to any one of the foregoing aspects, wherein the vehicle seat cushion component is included in the vehicle seat backrest or the vehicle seat bottom.

[0035] 24. The seat support according to any one of aspects 22 or 23, wherein the first plurality of three-dimensional loops, the second plurality of three-dimensional loops and the third plurality of three-dimensional loops each independently include a plurality of fused joints, in which two loops are attached to each other.

[0036] 25. The seat support according to any one of aspects 22 to 24, wherein the first plurality of three-dimensional loops and the second plurality of three-dimensional loops are each independently formed in the form of a vehicle seat cushion.

[0037] 26. The seat support according to any one of aspects 22 to 25, wherein the first plastic mesh cushion and the second plastic mesh cushion are each disposed above the first surface.

[0038] 29. The seat support according to any one of aspects 22 to 26, wherein the first plastic mesh cushion is attached to the first edge, and the second plastic mesh cushion is attached to the second edge.

[0039] 30. The seat support according to any one of aspects 22 to 29, wherein the first plastic mesh cushion and the second plastic mesh cushion are attached to the plastic mesh base by hook and loop strips, adhesives, retaining clips and / or clamps.

[0040] 31. The seat support according to any one of aspects 22 to 30, wherein at least a subset of the loops in the first plurality of three-dimensional loops, at least a subset of the loops in the second plurality of three-dimensional loops, and at least a subset of the loops in the third plurality of three-dimensional loops are not parallel or misaligned with each other.

[0041] 32. The seat support according to any one of aspects 22 to 31, wherein at least a subset of the rings in the first plurality of three-dimensional loops, at least a subset of the rings in the second plurality of three-dimensional loops, and at least a subset of the rings in the third plurality of three-dimensional loops are randomly oriented.

[0042] 33. The seat support according to any one of aspects 22 to 32 further includes a first skin layer disposed on the first surface of the plastic mesh base.

[0043] 34. The seat support according to any one of aspects 22 to 33 further includes a first skin layer disposed on the second surface of the plastic mesh base.

[0044] 35. The seat support according to any one of aspects 22 to 34, wherein the first plastic mesh cushion, the first plastic mesh cushion and the plastic mesh base independently comprise 60% to 95% by volume air.

[0045] 36. The seat support according to any one of aspects 22 to 35, wherein the first plastic mesh cushion, the first plastic mesh cushion, and the plastic mesh base each have an individual weight of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0046] 37. The seat support according to any one of aspects 22 to 36, wherein the first thermoplastic polymer, the second thermoplastic polymer and the third thermoplastic polymer are each independently extruded thermoplastic polymers.

[0047] 38. The seat support according to any one of aspects 22 to 37, 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.

[0048] 39. The seat support according to any one of aspects 22 to 38, wherein the first thermoplastic polymer, the second thermoplastic polymer and the third thermoplastic polymer are each independently linear low-density polyethylene.

[0049] 40. The seat support according to any one of aspects 22 to 39, wherein the first plurality of three-dimensional loops, the second plurality of three-dimensional loops and the third plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex.

[0050] 41. The seat support according to aspect 1, wherein the plurality of layers of the plastic mesh further include:

[0051] A first plastic mesh pillow, the first plastic mesh pillow comprising a first plurality of three-dimensional filament loops made of a first thermoplastic polymer;

[0052] A second plastic mesh pillow, the second plastic mesh pillow comprising a second plurality of three-dimensional filament loops composed of a second thermoplastic polymer; and

[0053] A plastic mesh substrate comprising a third plurality of three-dimensional loops made of a third thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first surface, and a second surface, wherein a first plastic mesh pad is attached to the plastic mesh substrate at the first edge, and a second plastic mesh pad is attached to the plastic mesh substrate at the first edge, wherein the first plurality of three-dimensional loops, the second plurality of three-dimensional loops, and the third plurality of three-dimensional loops each independently include a plurality of fused joints, in which two loops are attached to each other.

[0054] 42. The seat support according to any one of the preceding aspects, wherein the vehicle seat cushion component is included in the vehicle seat backrest or the vehicle seat bottom.

[0055] 43. The seat support according to any one of aspects 22 to 42, wherein the plastic mesh base has 60% to 95% air by volume.

[0056] 44. The seat support according to any one of aspects 22 to 43, 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.

[0057] 45. The seat support according to aspect 1 further includes:

[0058] The first pillow assembly includes a first core pad portion surrounded by a first outer pillow cover, the first outer pillow cover being surrounded by a first pillow decorative cover;

[0059] The second pillow assembly includes a second core pad portion surrounded by the second outer pillow cover; and

[0060] The decorative covering portion has a first edge and a second edge, the first cushion assembly is sewn to the decorative covering portion at the first edge, and the second cushion assembly is sewn to the decorative covering portion at the second edge.

[0061] 46. ​​The seat support according to any one of the preceding aspects, wherein the vehicle seat cushion component is included in the vehicle seat backrest or the vehicle seat bottom.

[0062] 47. The seat support according to any one of aspects 45 to 46, wherein the first cushion assembly and the second cushion assembly are each formed independently by compression molding.

[0063] 48. The seat support according to any one of aspects 45 to 47, wherein the first outer pillow cover and the second outer pillow cover each independently comprise a nonwoven fabric.

[0064] 49. The seat support according to any one of aspects 45 to 48, wherein the first outer cushion cover and the second outer cushion cover each independently comprise natural fibers.

[0065] 50. The seat support according to any one of aspects 45 to 49 further includes a central padding member positioned in an opening defined by the trim covering portion.

[0066] 51. The seat support according to any one of aspects 45 to 50, wherein the first core pad portion, the second core pad portion and the central pad component are each independently made of foamed polyurethane.

[0067] 52. The seat support according to any one of aspects 45 to 51, wherein the first core pad portion, the second core pad portion and the central pad component are each independently composed of a plurality of three-dimensional loops, the plurality of three-dimensional loops being composed of a thermoplastic polymer.

[0068] 53. The seat support according to any one of aspects 45 to 52, wherein the plurality of three-dimensional loops include a plurality of fused connections, in which two loops are attached to each other.

[0069] 54. The seat support according to any one of aspects 45 to 53, wherein at least a subset of the loops in the plurality of three-dimensional loops are not parallel or misaligned with each other.

[0070] 55. The seat support according to any one of aspects 45 to 54, wherein the first core pad portion, the second core pad portion and the central pad component independently have 60% to 95% air by volume.

[0071] 56. The seat support according to any one of aspects 45 to 55, wherein the first core pad portion, the second core pad portion, and the central pad component each independently have approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0072] 57. The seat support according to any one of aspects 45 to 56, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0073] 58. The seat support according to any one of aspects 45 to 57, 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.

[0074] 59. The seat support according to any one of aspects 45 to 58, wherein the thermoplastic polymer is a biodegradable or recyclable polymer.

[0075] 60. The seat support according to any one of aspects 45 to 59, wherein the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0076] 61. The seat support according to any one of aspects 45 to 60 further includes providing sound insulation and temperature cushioning.

[0077] 62. The seat support according to aspect 1 further includes a vehicle seat cushion component, the vehicle seat cushion component comprising: the plastic mesh substrate including a plurality of three-dimensional loops made of the thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first surface, and a second surface; a first foamed pad attached to the plastic mesh substrate at the first edge; and a second foamed pad attached to the plastic mesh substrate at the second edge.

[0078] 63. The seat support according to aspect 62, wherein the vehicle seat cushion component is included in the vehicle seat backrest or the vehicle seat bottom.

[0079] 64. The seat support according to any one of aspects 62 to 63, wherein the plurality of three-dimensional loops include a plurality of fused connections, in which two loops are attached to each other.

[0080] 65. The seat support according to any one of aspects 62 to 64, wherein the first foam cushion and the second foam cushion are each independently composed of a foamed polymer.

[0081] 66. The seat support according to any one of aspects 62 to 65, wherein the first foam cushion and the second foam cushion are each independently made of foamed polyurethane.

[0082] 67. The seat support according to any one of aspects 62 to 66, wherein the first foam cushion and the second foam cushion are each at least partially disposed above the first surface.

[0083] 68. The seat support according to any one of aspects 62 to 67, wherein the first foam pad is attached to the first edge, and the second foam pad is attached to the second edge.

[0084] 69. A seat support according to any one of aspects 62 to 68, wherein the first foam cushion is attached to the plastic mesh base using a first retaining clip, and the first foam cushion 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 respective first foam cushion or second foam cushion, and a retaining clip end attached to the plastic mesh base.

[0085] 70. The seat support according to any one of aspects 62 to 69, wherein at least a subset of the loops in the plurality of three-dimensional loops are not parallel or misaligned with each other.

[0086] 71. The seat support according to any one of aspects 62 to 70, wherein the rings in the plurality of three-dimensional loops are randomly oriented.

[0087] 72. The seat support according to any one of aspects 62 to 71, wherein the plastic mesh base has 60% to 95% air by volume.

[0088] 73. The seat support according to any one of aspects 62 to 72, wherein the plastic mesh base has a density of about 0.01 g / cm³. 3Up to 0.200 g / cm 3 The density.

[0089] 74. The seat support according to any one of aspects 62 to 73, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0090] 75. The seat support according to any one of aspects 62 to 74, 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.

[0091] 76. The seat support according to any one of aspects 62 to 75, wherein the thermoplastic polymer comprises linear low-density polyethylene.

[0092] 77. The seat support according to any one of aspects 62 to 76, wherein the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0093] 78. The seat support according to aspect 1 further includes 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 loops, the three-dimensional loops being made of a thermoplastic polymer.

[0094] 79. The seat support according to aspect 78, wherein the vehicle seat cushion component is included in the vehicle seat backrest or the vehicle seat bottom.

[0095] 80. The seat support according to any one of aspects 78 to 79, wherein the plurality of three-dimensional loops include a plurality of fused connections, in which two loops are attached to each other.

[0096] 81. The seat support according to any one of aspects 78 to 80, wherein the loops in the plurality of three-dimensional loops are randomly oriented.

[0097] 82. The seat support according to any one of aspects 78 to 81, wherein the plastic mesh base has 60% to 95% air by volume.

[0098] 83. The seat support according to any one of aspects 78 to 82, 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.

[0099] 84. The seat support according to aspect 1 further includes an assembly, the assembly further including: the at least one fabric sized to be displaced on the surface of the cushion; and the at least one retainer coupled to the at least one fabric along the periphery of the fabric to receive the trim element, the actuator, the heat transfer layer, or any combination thereof.

[0100] 85. The seat support according to aspect 84, further comprising the cushion.

[0101] 86. The seat support according to aspect 85, wherein the cushion further comprises a twisted mesh material.

[0102] 87. The seat support according to aspect 85 or 86 further includes a decorative cover sized to at least partially surround the cushion and the at least one fabric, wherein the decorative cover is coupled to the at least one retainer.

[0103] 88. The seat support according to aspects 84 to 87, wherein the at least one retainer includes at least one clamping ring.

[0104] 89. The seat support according to aspects 84 to 88, wherein the at least one retainer is not directly coupled to the cushion.

[0105] 90. The seat support according to aspects 84 to 89, wherein the at least one fabric further comprises a non-woven material.

[0106] 91. The seat support according to aspect 80, wherein the nonwoven material further comprises jute.

[0107] 92. The seat support according to aspect 1, further comprising: a member comprising a twisted 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 defined 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.

[0108] 93. The seat support according to aspect 92, wherein the component is formed solely of the stranded mesh material.

[0109] 94. The seat support according to aspect 93, wherein the stranded mesh material comprises a polymer mesh having a plurality of integrated polymer strands.

[0110] 95. The seat support according to any one of aspects 92 to 94, wherein the first end region is shaped to define a seat backrest pad; and wherein the second end region is shaped to define a seat base pad.

[0111] 96. The seat support according to any one of aspects 92 to 95, wherein the member further comprises a first surface for supporting an occupant on the cushion and a second surface opposite to 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.

[0112] 97. The seat support according to aspect 96, wherein the member defines one or more channels, each channel intersecting one of the first surface and the second surface.

[0113] 98. The seat support according to aspect 97, wherein the channel extends laterally across the member and is positioned between the first end region and the second end region.

[0114] 99. The seat support according to any one of aspects 97 to 98, wherein the channel includes a first surface and a second surface, wherein the first surface and the second surface mate with each other.

[0115] 100. The seat support according to aspect 99 further includes one or more channel fasteners that connect the first face to the second face to hold the first end region at the non-zero angle relative to the second end region.

[0116] 101. The seat support according to any one of aspects 92 to 100, further comprising one or more auxiliary members supported by said member.

[0117] 102. The seat support according to aspect 101, wherein the auxiliary component comprises a twisted mesh material.

[0118] 103. The seat support according to any one of aspects 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.

[0119] 104. The seat support according to any one of aspects 101 to 103, further comprising one or more auxiliary member fasteners for connecting the auxiliary member to the member.

[0120] 105. The seat support according to any one of aspects 101 to 104, wherein the auxiliary member is shaped and positioned on the member to form a side cushion or lumbar support.

[0121] 106. A seat assembly comprising: a base plate adapted to be mounted to a seat frame; and a seat support member according to any one of the preceding aspects, the seat support member being stacked on the base plate.

[0122] 107. The seat assembly according to aspect 106, wherein the substrate is formed of an elastomeric material.

[0123] 108. The seat assembly according to aspect 106 or 107, wherein the substrate is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

[0124] 109. The seat assembly according to any one of aspects 106 to 108 further includes a seat frame, wherein the base plate is attached to the seat frame.

[0125] 110. A seat assembly comprising: a seat frame; and a seat support member according to any one of aspects 1 to 105, the seat support member being attached to or supported by the seat frame.

[0126] 111. A seat assembly comprising: a seat base; a seat back; and a seat support according to any one of aspects 1 to 105, the seat support being located in the seat base or the seat back.

[0127] 112. A vehicle seat, comprising:

[0128] The bottom of the seat, wherein the bottom of the seat has a seat bottom frame;

[0129] A seat backrest, the seat backrest being attached to the bottom of the seat, the seat backrest including a seat backrest frame; and

[0130] The seat support according to any one of aspects 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:

[0131] The first pillow assembly includes a first core pad portion surrounded by a first outer pillow cover, the first outer pillow cover being surrounded by a first pillow decorative cover;

[0132] The second pillow assembly includes a second core pad portion surrounded by a second outer pillow cover, the second outer pillow cover being surrounded by a second pillow trim cover; and

[0133] The decorative covering portion has a first edge and a second edge, the first cushion assembly is sewn to the decorative covering portion at the first edge, and the second cushion assembly is sewn to the decorative covering portion at the second edge.

[0134] 113. The vehicle seat according to aspect 112, wherein the first outer pillow cover and the second outer pillow cover each independently comprise a nonwoven fabric.

[0135] 114. The vehicle seat according to any one of aspects 112 to 113, wherein the first outer cushion cover and the second outer cushion cover each independently comprise natural fibers.

[0136] 115. The vehicle seat according to any one of aspects 112 to 114, wherein the vehicle seat cushion component further includes a central cushion component positioned in an opening defined by the trim cover portion.

[0137] 116. The vehicle seat according to any one of aspects 112 to 115, wherein the first core pad portion, the second core pad portion and the central pad component are each independently made of foamed polyurethane.

[0138] 117. A vehicle seat according to any one of aspects 112 to 116, wherein the first core pad portion, the second core pad portion and the central pad component are each independently composed of a plurality of three-dimensional loops made of a thermoplastic polymer.

[0139] 118. A vehicle seat according to any one of aspects 112 to 117, wherein the plurality of three-dimensional loops include a plurality of fused joints, in which two loops are attached to each other.

[0140] 119. A vehicle seat according to any one of aspects 112 to 118, wherein at least a subset of the loops in the plurality of three-dimensional loops are not parallel or misaligned with each other.

[0141] 120. A vehicle seat according to any one of aspects 112 to 119, wherein the first core pad portion and the second core pad portion have 60% to 95% air by volume.

[0142] 121. A vehicle seat according to any one of aspects 112 to 120, wherein the first core pad portion and the second core pad portion each independently have about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0143] 122. A vehicle seat according to any one of aspects 112 to 121, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0144] 123. A tool comprising: a die defining a series of orifices arranged to extrude material for the stranded mesh material member for the padding according to any one of aspects 92 to 105, the series of orifices being arranged to define an outer periphery of the member, the outer periphery including a seat back region and a seat base region.

[0145] 124. The tool according to aspect 123, wherein the series of orifices is further arranged such that the outer periphery defines one or more channels for the member.

[0146] 125. The tool according to aspect 124, wherein the series of orifices are arranged such that the one or more channels are positioned between the seat back area and the seat base area.

[0147] 126. A method of manufacturing a product, the method comprising:

[0148] a) A first sub-method, the first sub-method comprising:

[0149] i) Unfold the first sheet of the first material.

[0150] ii) Cut the first seat support layer from the first sheet.

[0151] iii) Mount the first seat support layer onto the substrate.

[0152] iv) Unfold a second sheet of the second material, the density of which is less than that of the first material.

[0153] v) Cut the second seat support layer from the second sheet, and

[0154] vi) Install the second seat support layer onto the first seat support layer;

[0155] b) The second sub-method, which includes:

[0156] i) Multiple layers or regions forming a plastic mesh, and

[0157] ii) Stacking or attaching the plurality of layers or regions relative to each other, or positioning the plurality of pad segments relative to each other at a non-zero angle;

[0158] c) A third sub-method, wherein the third sub-method includes:

[0159] i) Sewing the first pillow assembly to the first edge of the decorative cover portion, the first pillow assembly having a first core padding portion surrounded by a first outer pillow cover, the first outer pillow cover being surrounded by the first pillow decorative cover, and

[0160] ii) Sew the second pillow assembly to the second edge of the decorative cover portion, the second pillow assembly having a second core padding portion surrounded by the second outer pillow cover;

[0161] d) A fourth sub-method, the fourth sub-method comprising:

[0162] i) Attaching a first foamed pad to a first edge of a plastic mesh substrate, the plastic mesh substrate comprising a plurality of three-dimensional loops made of a thermoplastic polymer, and

[0163] ii) Attach the second foamed pad to the second edge of the plastic mesh base; and / or

[0164] e) A fifth sub-method, the fifth sub-method comprising:

[0165] i) Attach at least one retainer to the periphery of at least one fabric.

[0166] ii) Stack the at least one fabric on the padding, and

[0167] iii) Connecting the decorative component, actuator, heat transfer layer or any combination thereof to the at least one retainer.

[0168] 127. The method according to aspect 126 further includes the first sub-method.

[0169] 128. The method according to aspect 126 or 127 further includes: 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 mounting the third seat support layer onto the second seat support layer.

[0170] 129. The method according to any one of aspects 126 to 128 further includes incorporating the second seat support layer into the first seat support layer.

[0171] 130. The method according to aspect 126 further includes the second sub-method.

[0172] 131. The method according to any one of aspects 126 and 130 further includes shaping the plurality of pad segments.

[0173] 132. The method according to any one of aspects 126, 130 and 131 further includes forming the plurality of pad segments into a single sheet.

[0174] 133. The method according to aspect 132 further includes folding the padding segments to stack the padding segments on top of each other.

[0175] 134. The method according to aspect 133 further includes forming at least one recess in at least one of the plurality of pad segments to fold the pad segment.

[0176] 135. The method according to any one of aspects 126 and 130 to 134 further includes cutting the plurality of pad segments to shape the plurality of pad segments.

[0177] 136. The method according to aspect 126 further includes the fifth sub-method.

[0178] 137. The method according to aspect 136 further includes at least partially surrounding the padding and the at least one fabric by attaching a decorative cover to the at least one retainer.

[0179] 138. The method according to aspects 136 to 137, wherein the at least one fabric further comprises a non-woven material.

[0180] 139. The method according to aspect 16 further includes: positioning a first end region of the stranded mesh material member of the plurality of pad segments at a non-zero angle relative to a second end region of the member; and holding the first end region at the non-zero angle relative to the second end region.

[0181] 140. The method according to aspect 139 further includes forming the stranded mesh material component by extruding material via a die.

[0182] 141. The method according to aspect 140, wherein the stranded mesh material member is extruded to form the first end region and the second end region.

[0183] 142. The method according to any one of aspects 140 to 141, wherein forming the stranded mesh material component further includes discharging the extruded material through a funnel from the mold.

[0184] 143. The method according to aspect 142 further includes moving the extruded material via one or more rollers after discharge.

[0185] 144. The method according to aspect 143 further includes forming one or more channels during at least one of the processes of extruding the material, discharging the extruded material, and moving the extruded material.

[0186] 145. The method according to any one of aspects 140 to 144 further includes cutting the one or more channels in the member.

[0187] 146. The method according to any one of aspects 144 to 145 further includes inserting one or more fasteners into opposite sides of the channel and / or combining the opposite sides of the channel to retain the first end region relative to the second end region.

[0188] 147. The method according to any one of aspects 140 to 146 further includes 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.

[0189] 148. The method according to any one of aspects 139 to 147 further includes bending the stranded mesh material member from a first position to a second position to orient the member.

[0190] 149. The method according to any one of aspects 139 to 148 further includes attaching one or more auxiliary components to said component.

[0191] 150. The method according to aspect 149 further includes forming the auxiliary member from a stranded mesh material.

[0192] 151. The method according to any one of aspects 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 combining the auxiliary member to the member.

[0193] 152. The method according to any one of aspects 139 to 151 further includes attaching the member to the frame of the seat assembly to provide padding for the frame of the seat assembly.

[0194] 153. A method for designing a seat cushion, the method comprising: obtaining a design for a monolithic seat cushion; and redesigning the monolithic seat cushion design into a design of multiple stacked, stitched, or attached seat cushion segments.

[0195] 154. The method according to aspect 153 further includes redesigning the monolithic seat cushion design into a plurality of stacked seat cushion segments, each having a common maximum thickness.

[0196] 155. A method of manufacturing a seat cushion, the method comprising: designing a plurality of cushion segments according to aspect 153 or 154; and forming the plurality of cushion segments by extruding a thermoplastic resin web.

[0197] 156. The method according to aspect 155 further includes stacking the plurality of pad segments as pads.

[0198] 157. A seat support, said seat support being manufactured by the method according to any one of aspects 139 to 152 or designed by the method according to any one of aspects 153 to 56.

[0199] 158. The method according to any one of aspects 139 to 156 further includes mounting the product to the seat frame.

[0200] 159. A seat assembly manufactured by the method according to aspect 158.

[0201] 160. A seat support manufactured by the method according to aspect 157, the method further comprising: coupling the at least one retainer to the periphery of the at least one fabric; stacking the at least one fabric on the cushion; and coupling the trim member, the actuator, the heat transfer layer, or any combination thereof to the at least one retainer.

[0202] 161. A seat support manufactured by the method according to aspect 160, the method further comprising compressing and molding the at least one fabric into the contour of the cushion before stacking the at least one fabric on the cushion.

[0203] 162. A seat support manufactured by the method according to aspects 160 to 161, the method further comprising attaching a decorative cover to the at least one retainer, the decorative cover being sized to at least partially surround the padding and the at least one fabric.

[0204] 163. A seat support manufactured by the method according to aspects 160 to 162, wherein stacking the at least one fabric on the pad further comprises stacking the at least one fabric on a twisted mesh material pad.

[0205] 164. A seat support manufactured by the method according to aspects 160 to 163, the method further comprising not directly attaching the at least one retainer to the cushion.

[0206] 165. A seat support manufactured by the method according to aspects 160 to 164, wherein the method further includes clamping at least one clamping ring to the fabric as the at least one retainer. Brief description of the attached diagram

[0207] To further understand the nature, purpose, and advantages of this disclosure, reference should be made to the following detailed description, which should be read in conjunction with the accompanying drawings, wherein similar reference numerals denote similar elements, and in the drawings:

[0208] Figure 1 This is a perspective cross-sectional view of a seat assembly according to some embodiments;

[0209] Figure 2 This is an exploded perspective view of multiple layers of a seat assembly according to some embodiments;

[0210] Figure 3 This is a side cross-sectional view of a seat assembly according to some embodiments;

[0211] Figure 3B Methods according to some embodiments are shown;

[0212] Figure 4 This is a front perspective view of a seat assembly according to some embodiments;

[0213] Figure 5 yes Figure 4 Front perspective view of the seat assembly padding;

[0214] Figure 6 yes Figure 5 Side view of the padding;

[0215] Figure 7 yes Figure 5 A schematic front view of the padding;

[0216] Figure 8 yes Figure 5 A front perspective view of a portion of the padding;

[0217] Figure 9 This is a side view of a portion of the liner according to some embodiments, shown in a first position;

[0218] Figure 10 yes Figure 9 Another side view of a portion of the padding, shown in the second position;

[0219] Figure 11 This is a front view of a liner according to some embodiments, shown in a partially disassembled state;

[0220] Figure 12 yes Figure 11 Rear view of the liner;

[0221] Figure 13 This is shown as after the intermediate assembly step. Figure 11 Another rear view of the liner;

[0222] Figure 14 It is shown as being after another assembly step. Figure 11 Another rear view of the liner;

[0223] Figure 15 It is shown as in Figures 11-14 After the assembly steps Figure 11 Front view of the liner;

[0224] Figure 16 This is a side front view of a liner according to some embodiments;

[0225] Figure 16B Methods according to some embodiments are shown;

[0226] Figure 16C Methods according to some embodiments are shown;

[0227] Figure 16D Methods according to some embodiments are shown;

[0228] Figure 17 It is a perspective view of the seats in a vehicle;

[0229] Figure 18A This is a front view of a vehicle seat cushion component with plastic mesh side bolsters;

[0230] Figure 18B This is a front view of a vehicle seat cushion component with plastic mesh side pillows;

[0231] Figure 19A It is a front view of a vehicle seat cushion component with plastic mesh side pads and one or more skin layers;

[0232] Figure 19B It is a front view of a vehicle seat cushion component with plastic mesh side pillows and one or more layers of skin.

[0233] Figure 20 This is a perspective view of a vehicle seat that incorporates a pair of cushion assemblies stitched to a trimcover;

[0234] Figure 21A This is a top view of a vehicle seat component, which includes a pair of cushion assemblies stitched to a decorative cover;

[0235] Figure 21B This is a cross-sectional view of a vehicle seat component, which includes a pair of cushion assemblies stitched to a decorative cover;

[0236] Figure 22 It is a perspective view of the seats in a vehicle;

[0237] Figure 23A This is a front view of a vehicle seat cushion component with foamed side bolsters;

[0238] Figure 23B This is a front view of a vehicle seat cushion component with foamed side pillows;

[0239] Figure 24A It is a front view of a vehicle seat cushion component with foamed side pillows and one or more layers of skin.

[0240] Figure 24B It is a front view of a vehicle seat cushion component with foamed side pillows and one or more layers of skin.

[0241] Figure 25 This is a perspective view of a seat assembly according to some embodiments;

[0242] Figure 26 yes Figure 25 A partial perspective view of the foam-free padding of the seat assembly;

[0243] Figure 27 It is attached to Figure 25 Partial top plan view of the cushion retainer components and other seat components;

[0244] Figure 27B Methods according to some embodiments are shown;

[0245] Figure 28 A perspective view of a seat assembly according to some embodiments is shown;

[0246] Figure 29 The illustration shows some embodiments and is used with Figure 28 A partial view of a portion of the cushioning used in conjunction with the seat components;

[0247] Figure 30 The following are illustrations of a method for using according to some embodiments. Figure 29 A schematic diagram of the manufacturing process of the liner;

[0248] Figure 31 It shows the use of with Figure 29 A top view of the extrusion direction used in the manufacturing process;

[0249] Figure 32 The use of a first configuration according to some embodiments is shown. Figure 31 The mold is formed and used with Figure 28 A partial side view of the padding used in conjunction with the seat components;

[0250] Figure 33 The second configuration is shown. Figure 32 A partial side view of the padding;

[0251] Figure 34 This shows a display with an insert. Figure 32 A partial side view of the padding;

[0252] Figure 35 It shows the use of with Figure 29 A top view of another component or example used in the manufacturing process;

[0253] Figure 36 The use of a first configuration according to some embodiments is shown. Figure 35 The mold is formed and used with Figure 28 A partial side view of the padding used in conjunction with the seat components;

[0254] Figure 37 The second configuration is shown. Figure 36 A partial side view of the padding; and

[0255] Figure 38 Methods according to some embodiments are shown. Detailed description

[0256] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. Numerous specific details are set forth in the following detailed description in order to provide a thorough understanding of the various embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described can be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0257] It should be understood that the disclosed embodiments are merely exemplary, and various forms and alternatives are possible. The drawings are not necessarily to scale; some features may be enlarged or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to implement embodiments according to this disclosure in various ways.

[0258] "One or more" includes functions performed by one element, functions performed by more than one element (e.g., in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0259] It should also be understood that although the terms first, second, etc., are used herein to describe various elements in certain circumstances, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first surface may be referred to as a second surface, and similarly, a second surface may 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.

[0260] The terminology used in the description of the various embodiments described herein is for the purpose of describing particular embodiments only and is 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.

[0261] It should also be understood that the term “and / or” as used herein refers to and covers any and all possible combinations of one or more of the associated listed items. 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” should mean “A only, or B only, or both A and B.” In the case of “A only,” the term also covers the possibility that B is not present, i.e., “A only, but no B.”

[0262] It should be further understood that, when used in this specification, the terms “includes,” “including,” “comprises,” and / or “comprising” specify the presence of the stated feature, integral, step, operation, element, and / or component, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof.

[0263] As used herein, the term "if" may optionally be interpreted as "when," "after," "in response to determination," or "in response to detection," depending on the context. Similarly, the phrases "if determination" or "if [the condition or event] is detected" may optionally be interpreted as "after determination," "in response to determination," "after [the condition or event] is detected," or "in response to the detection of [the condition or event]," depending on the context.

[0264] Except where explicitly stated in the examples or otherwise, all numerical quantities indicating the amount of material or the conditions of reaction and / or use in this description shall be understood to be modified by the word “about” when describing the broadest scope of the invention. Practice within the stated numerical limits is generally preferred. Furthermore, unless explicitly stated to the contrary: percentages, “parts of…”, and proportions are by weight; the term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” and the like; the molecular weight provided for any provided polymer is a weight-average molecular weight unless otherwise specified; a description of a group or class of materials suitable or preferred for a given purpose in relation to the invention means that a mixture of any two or more members of that group or class is equally suitable or preferred; descriptions of components in chemical terms refer to components when added to any combination specified in the description and do not necessarily exclude chemical interactions between components of the resulting mixture; the first definition of acronyms or other abbreviations applies to all subsequent uses of the same abbreviations herein, and common grammatical variations of the initially defined abbreviations are applied with the necessary modifications; and unless explicitly stated to the contrary, performance measurements are determined by the same technique as mentioned above or below for the same performance.

[0265] As used herein, the term "about" means that the quantity or value in question can be a specific value or some other value in its neighborhood. Generally, the term "about" to indicate a value is intended to represent a range within + / - 5% of that value. As an example, the phrase "about 100" represents a range of 100 + / - 5, that is, a range from 95 to 105. Generally, when the term "about" is used, it can be expected that similar results or effects according to the invention can be obtained within + / - 5% of the indicated value.

[0266] 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 can certainly vary. Furthermore, the terminology used herein is for the purpose of describing specific embodiments of the invention only and is not intended to be limiting in any way.

[0267] 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 methodological steps.

[0268] The phrase "consisting of" excludes any element, step, or component not specified in the claim. When this phrase appears in a clause of the body of a claim rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0269] The phrase "consisting essentially of" limits the scope of the claim to the specified material or step, plus those material or steps that do not substantially affect the basic and novel characteristics of the claimed subject matter.

[0270] The phrase "composed of" means "including" or "consisting of". It is typically used to indicate that an object is formed from materials.

[0271] Regarding the terms “comprising,” “consisting of,” and “consisting essentially of,” if one of these three terms is used herein, the subject matter currently disclosed may include the use of either of the other two terms.

[0272] 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."

[0273] The terms “substantially,” “generally,” or “about” are used herein to describe the disclosed or claimed embodiments. The term “substantially” may modify a value or relative characteristic disclosed or claimed in this disclosure. In such cases, “substantially” may mean that the value or relative characteristic it modifies is within ±0%, ±0.1%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, or ±10% of that value or relative characteristic.

[0274] It should also be recognized that an integer range explicitly includes all integers in between. For example, the integer range 1 to 10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4, ..., 97, 98, 99, and 100. Likewise, when any range is required, the middle number obtained by dividing the difference between the upper and lower limits by 10 as the increment can be considered an optional upper or lower limit. For example, if the range is 1.1 to 2.1, then the numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be chosen as either the lower or upper limit.

[0275] When numerical quantities are involved, in specific examples, the term "less than" includes a lower non-included limit, that is, 5% of the value indicated after "less than". For example, in a specific example, "less than 20" includes a lower limit of 1 that is not included. Therefore, such a specific example of "less than 20" includes the range between 1 and 20. In another specific example, the term "less than" includes a lower limit that is not included, that is, 20%, 10%, 5%, or 1% of the value indicated after "less than", in a preferred ascending order.

[0276] Seating assemblies and vehicle seating assemblies are designed and manufactured to various specifications, including support, comfort, performance, heating, ventilation, cooling, and adjustability. Seating assemblies typically feature a frame and various layers of foam with different densities to accommodate appropriate load distribution throughout the seating assembly.

[0277] Figure 1 A seat assembly 20 according to an embodiment is shown. The seat assembly 20 is depicted as a vehicle seat and can be used as a seat assembly in land vehicles, aircraft, ships, 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 conventional foam to improve support and comfort while reducing cost, materials, and size. The seat assembly 20 can also employ recyclable materials manufactured for further recycling at the end of its use.

[0278] Seat assembly 20 includes a seat base 22 sized to receive a seated occupant and support the occupant's pelvis and thighs. Seat assembly 20 also includes a seat back 24 sized to extend upright from seat base 22 to support the occupant's back. A headrest may also be supported on and above seat back 24 to support the occupant's head. Seat base 22 is adapted to be supported by an underlying support surface. For the depicted embodiment, seat assembly 20 includes a pair of rails 28 for mounting seat base 22 to a vehicle floor for fore-and-aft adjustment relative to the vehicle floor. Seat back 24 may also be adjustable to tilt relative to seat base 22. The headrest may also be adjustable in height, tilt, and forward / rear direction. Other adjustments may be provided as known in the art.

[0279] The seat base 22 includes a frame 30 for providing rigid structural support for the seat base 22. The seat back 24 may also include a frame connected to the seat base frame 30 to extend upright from the seat base 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.

[0280] A typical seat assembly comprises multiple layers of foam that work together to provide cushioning on the frame 30. Variations in the density of the foam layers provide compliant support to the occupant while distributing force from the occupant to the frame 30. The foam layers also provide comfort to the occupant. The foam layers are typically molded, therefore each foam layer for each seat assembly requires specialized tools.

[0281] 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 multiple stacked layers of non-foam material. The seat back 24 includes a seat back support 38, also formed from non-foam stacked layers. Similarly, the headrest may also be provided with a headrest support formed from non-foam stacked layers.

[0282] Figure 1The illustration shows multiple stacked layers 40, 42, 44, 46, 48, 50, and 52 used to construct the seat bottom support 36, seat back support 38, and headrest support. Each of the stacked layers 40, 42, 44, 46, 48, 50, and 52 can have a varying material density. The stacked layers 40, 42, 44, 46, 48, 50, and 52 can have a decreasing material density and firmness from the base layer 40 to the intermediate layers 42, 44, 46, 48, and 50, and to the comfort layer 52. The stacked layers 40, 42, 44, 46, 48, 50, and 52 provide a transition in density and firmness from the comfort support at the occupant contact surface at the comfort layer 52 to the structural support at the base layer 40.

[0283] For the depicted embodiments, the substrate 40 may be formed of a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride. The substrate 40 may serve as a substrate or shell for the intermediate layers 42, 44, 46, 48, 50, and the comfort layer 52. The substrate 40 may be directly mounted to the frame 30. The substrate 40 may have a suitable thickness, such as two millimeters or less.

[0284] Stacking layers 40, 42, 44, 46, 48, 50, and 52 are in... Figure 2 The diagram shows multiple sheets. Sheets 40, 42, 44, 46, 48, 50, and 52 are each unwound from a material roll. Sheets 40, 42, 44, 46, 48, 50, and 52 are unwound to a flat surface. The flatness is approximately planar within manufacturing tolerances. Each of the material rolls can be a commercially available material roll, such as materials used for vehicle interiors, floorboards, acoustics, etc. Examples of such materials include rubber, thick blankets, needle-punched cotton shoddy, polyethylene terephthalate, linear low-density polyethylene, polypropylene, etc. By utilizing existing materials, material and manufacturing costs are reduced compared to molding foam linings using specialized tools. The material can also be formed from recycled materials to reduce material costs and waste. According to another embodiment, one or more of layers 40, 42, 44, 46, 48, 50, and 52 can be formed from extruded thermoplastic resin webs, as described in subsequent embodiments.

[0285] After layers 40, 42, 44, 46, 48, 50, and 52 are unfolded into sheets 40, 42, 44, 46, 48, 50, and 52, the sheets 40, 42, 44, 46, 48, 50, and 52 are then die-cut into seat support layers 40, 42, 44, 46, 48, 50, and 52 to collectively provide the contour of the seat base 22. The seat support layers 40, 42, 44, 46, 48, 50, and 52 are then stacked and joined or combined together. The seat support layers 40, 42, 44, 46, 48, 50, and 52 may be welded, sewn, fastened, adhered, or otherwise connected to sequentially adjacent seat support layers 40, 42, 44, 46, 48, 50, and 52. Alternatively, sheets 40, 42, 44, 46, 48, 50, and 52 can be stacked or stacked and combined prior to the cutting operation. The cutting operation can be performed by one or more dies. The tooling cost of the cutting dies reduces capital costs compared to dedicated molding tools. Alternatively, robotic laser cutting or other flexible automation can be used to reduce tooling costs; this robotic laser cutting or other flexible automation can be programmed to cut various seating arrangements.

[0286] Layers 40, 42, 44, 46, 48, 50, and 52 can be customized. Each layer can achieve a specific firmness and thickness, allowing different combinations of layers 40, 42, 44, 46, 48, 50, and 52 to optimize specific support and comfort profiles for various seats. The comfort profile is formed by estimating the pressure distribution throughout the seat assembly 20 based on design features set for the occupant according to predicted height, weight, and other data within the target range of the occupant. Using stacked layers 40, 42, 44, 46, 48, 50, and 52 instead of polyurethane foam and designed to provide the same static comfort results in a lighter seat assembly 20 compared to one made of foam. Furthermore, stacked layers 40, 42, 44, 46, 48, 50, and 52 allow for greater design flexibility to reduce pressure in peak areas of the seat assembly 20.

[0287] Figure 3 A seat support 54 according to some embodiments is shown. The outer shell or base plate 40 may be formed with a profile rather than being formed from a flat sheet 40. Then, intermediate layers 42, 44, 46 and comfort layer 52 are mounted on the base plate 40.

[0288] Refer again Figure 1Once the stacked layers 40, 42, 44, 46, 48, 50, and 52 are assembled, the seat supports 36 and 38 are installed in the seat assembly 20. Decorative covers 60 and 62 are provided above each seat support 36 and 38 to surround and conceal the seat supports 36 and 38.

[0289] By removing foam from seat assembly 20, molding tools and molds can be eliminated, reducing tooling costs. The flexibility of die-cutting, laser cutting, or other automated processes reduces maintenance costs and improves part quality. Material recyclability reduces waste. Additionally, the use of chemicals during manufacturing is reduced.

[0290] Seat assembly 20 is lighter than similar seats made with foam padding. Seat assembly 20 is also more compact in size, for example, with a depth of 35 mm to 40 mm, while providing similar or improved comfort. It offers layers of targeted comfort and can be easily redesigned for future models or options without additional tooling costs.

[0291] Figure 3B Method 400 according to some embodiments is illustrated. Method 400 is used to manufacture a seating assembly (e.g., seating assembly 20, 120, 210, 310, 410, 520, 620), which may be a vehicle seat, office chair, personal chair, and / or the like. In various examples, method 400 may have more or fewer steps than described below, and the steps may be performed in a different order, sequentially, or simultaneously. Method 400 may be a method of manufacturing a product, which may be a vehicle seat, office chair, personal chair, cushion, seat support, seat bottom cushion, seat back cushion, headrest, etc.

[0292] Method 400 includes unfolding (402) a first sheet of a first material, which may be generally planar within manufacturing tolerances. The first material may have or not have foam, rubber sheets, thick blankets, needle-punched cotton fabrics, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recyclable materials, and / or materials unfolded from material rolls. Each of the material rolls may be a commercially available material roll, such as materials used for vehicle interiors, floorboards, audio systems, etc. Method 400 includes, for example, cutting (404) from the first sheet (which may be die-cutting, robotic laser cutting, waterjet cutting, laser cutting, or other flexible automation) a first seat support layer (e.g., intermediate layer 42) for seat bottoms, seat backs, headrests, etc., and mounting (406) the first seat support layer (e.g., intermediate layer 42) onto 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 intermediate layer, and the comfort layer can be formed with contours rather than from a flat sheet. Method 400 includes unrolling (408) a second sheet of a second material with a density less than that of the first material. The second sheet can be generally 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 second material may have or not have foam, rubber sheets, thick blankets, needle-punched cotton fabrics, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recyclable materials, and / or materials each unrolled from a material roll. Each of the material rolls can be a commercially available material roll, such as materials used for vehicle interiors, floorboards, audio systems, and / or the like. Method 400 includes cutting (410) from a second sheet (which may be die-cut, robotic laser-cut, waterjet-cut, laser-cut and / or other flexible automation) a second seat support layer (e.g., intermediate layer 44) for seat bottom, seat back, headrest and / or the like, and mounting (412) the second seat support layer (e.g., intermediate layer 44) onto a first seat support layer (e.g., intermediate layer 42).

[0293] In some embodiments, method 400 includes unfolding a third sheet of a third material with a density less than that of the second material. This third sheet may be generally planar within manufacturing tolerances, providing 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 have or not have foam, rubber sheets, thick blankets, needle-punched cotton fabrics, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recycled materials, and / or materials unfolded from material rolls. Each of the material rolls may be a commercially available roll, such as materials used for vehicle interiors, floorboards, audio systems, and / or the like. Method 400 includes cutting (which may be die-cut, robotic laser-cut, waterjet-cut, laser-cut, and / or other flexible automated methods) a third seat support layer (e.g., intermediate layer 46) from the third sheet and mounting the third seat support layer (e.g., intermediate layer 46) onto a second seat support layer (e.g., intermediate layer 44).

[0294] In some embodiments, method 400 includes bonding a second seat support layer (e.g., intermediate layer 44) to a first seat support layer (e.g., intermediate layer 42). This bonding can be provided by: a retaining clip (having an end embedded in 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 hog ring, a single- or double-sided retention clip, welding, stitching, fastening, adhesion, heat-staked, and / or other methods of retention.

[0295] Seating assemblies (e.g., seating assembly 20) are described, which may be vehicle seats, office chairs, personal chairs, and / or the like. In some embodiments, the seating assemblies (e.g., 20, 120, 210, 310, 410, 520, 620) are manufactured using method 400.

[0296] Seat supports (e.g., seat supports 36, 38, and / or 54) are described, which may be seat bottom padding, seat back padding, headrest, headrest, cushion, area, section, and / or the like. Seat supports (e.g., seat supports 36, 38, and / or 54) include multiple flat layers (e.g., intermediate layers 42-50), which may be substantially planar within manufacturing tolerances, and may have or not have foam, rubber sheets, thick blankets, needle-punched cotton fabrics, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recyclable materials, and / or materials each unwound from a roll of materials. Each of the rolls of materials may be a roll of materials readily available on the market, such as materials used for vehicle interiors, floorboards, audio systems, and / or the like. Multiple flat layers are used for mounting to and supporting the occupant on the seat frame, which may be a stamped steel alloy, fiber-reinforced polymer, or any suitable structural material, wire suspension mats, a substrate, and / or a panel. Multiple flat layers (e.g., intermediate layers 42-50) are stacked on top of each other (e.g., as shown in the image). Figures 2-3 As shown), and each of the multiple stacked layers has a varying density, which can provide a transition in density and solidity from comfort support at the occupant contact surfaces at the comfort layer to structural support at the base layer.

[0297] 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). This provides a transition in density and robustness from comfort support at the occupant contact surface in the comfort layer to structural support in the base 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 base layer may serve as a substrate or shell for the intermediate and comfort layers.

[0298] In some embodiments, the solidity 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). This provides a transition in density and solidity from comfort support at the occupant contact surface in the comfort layer to structural support in the base 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 base layer may serve as a substrate or shell for the intermediate and comfort layers.

[0299] In some embodiments, multiple stacked layers (e.g., intermediate layers 42-50) are joined together, and the connection may utilize the following: retaining clips (the retaining clips having an end embedded in the layer and a retaining clip end attached to the plastic mesh substrate), hook and loop connector strips, hook layers, loop layers, adhesives, clamp rings, single-sided or double-sided retaining clips, bonding, welding, stitching, fastening, adhesion, thermal riveting and / or retaining.

[0300] In some embodiments, each sequential pair of multiple stacked layers (e.g., intermediate layers 42-50) (e.g., layers 42 and 44; layers 46 and 48) is combined together, which may utilize the following: retaining clips (the retaining clips having an end embedded in the layer and a retaining clip end attached to the plastic mesh substrate), hook and loop connector strips, hook layers, loop layers, adhesives, clamp rings, single-sided or double-sided retaining clips, welding, stitching, fastening, adhesion, thermal riveting, and / or retention.

[0301] In some embodiments, each sequential pair of multiple stacked layers (e.g., intermediate layers 42-50) (e.g., layers 42 and 44; layers 46 and 48) is welded, stitched, fastened, or adhered together.

[0302] In some embodiments, the plurality of stacked layers (e.g., intermediate layers 42-50) further include rubber, thick blanket, needle-punched cotton fabric, polyethylene terephthalate, or polypropylene.

[0303] In some embodiments, the plurality of stacked layers (e.g., layers 40-50) further include a base layer (e.g., layer 40) adapted for mounting to a seat frame, wherein the base layer (e.g., layer 40) is formed of a denser material than the other layers in the plurality of stacked layers, the material being a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer may serve as a substrate or shell for the intermediate layer and / or comfort layer.

[0304] In some embodiments, the base layer (e.g., layer 40) is formed of an elastomeric material, such as a high-density material (e.g., 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.

[0305] In some embodiments, the base layer (e.g., 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 comfort layer.

[0306] In some embodiments, the base layer (e.g., layer 40) has a thickness of two millimeters or less.

[0307] 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 methods 1600, 1650, 1680, 2700, 3800.

[0308] A seating assembly (e.g., seating assembly 20) is described, which may be a vehicle seat, office chair, personal chair, and / or the like. In some embodiments, the seating assembly (e.g., 20, 120, 210, 310, 410, 520, 620) is manufactured using method 400. The seating assembly includes a substrate (e.g., layer 40) adapted for mounting to a seat frame, and seat supports (e.g., seat supports 36, 38, and / or 54) are stacked on the substrate.

[0309] In some embodiments, the substrate (e.g., layer 40) 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 the comfort layer may be formed with contours rather than from a flat sheet. In some embodiments, the substrate is formed of an elastomeric material, such as a high-density material (e.g., an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride). The base layer may provide a substrate or shell for both the intermediate layer and the comfort layer.

[0310] In some embodiments, the substrate (e.g., layer 40) is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride.

[0311] 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 the substrate (e.g., layer 40) is attached to the seat frame.

[0312] Seat supports (e.g., seat supports 36, 38, and / or 54) are described, which may be seat bottom pads, seat back pads, headrests, headrests, cushions, areas, sections, and / or the like. Seat supports (e.g., seat supports 36, 38, and / or 54) comprise multiple flat layers (e.g., layers 40-50), which may be substantially planar within manufacturing tolerances, and which may or may not contain foam, rubber sheets, thick blankets, needle-punched cotton fabrics, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, expanded polyvinyl chloride, recyclable materials, and / or materials each unwound from a roll of materials. Each of the rolls of materials may be a roll of materials readily available on the market, such as materials used for vehicle interiors, floorboards, audio systems, and / or the like. Multiple flat layers are used for mounting to and supporting the occupant on a seat frame, which may be a stamped steel alloy, fiber-reinforced polymer, or any suitable structural material, wire suspension pad, substrate, and / or panel. The multiple flat layers (e.g., layers 40-50) are stacked on top of each other, and the density of the stacked layers (e.g., layers 40-50) varies sequentially from the occupant support surface (e.g., layer 50) to the base layer (e.g., layer 40). This provides a transition in density and firmness from comfortable support at the occupant contact surface at the comfort layer to structural support at the base layer. The multiple stacked layers may include high-density materials such as elastomers, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer may serve as a substrate or shell for the intermediate and comfort layers.

[0313] Figure 4 A seat assembly 120 as a vehicle seat assembly 120 according to some embodiments is shown. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 can be used. The seat assembly 120 can be used in land vehicles, aircraft, ships, etc. The seat assembly 120 can also be used in office chairs, comfort chairs, etc.

[0314] The depicted seat assembly 120 includes a seat base pad 122 to support the pelvis and thighs of a seated occupant. The seat assembly 120 also includes a seat back pad 124 to support the back and shoulders of a seated occupant. A decorative cover 126 is disposed above the seat pads 122 and 124 to conceal the seat pads 122 and 124 and to provide a uniform and smooth contact surface for the occupant.

[0315] Figures 5-7 The image shows the seat bottom liner 122 as detached from the seat assembly 120. The seat bottom liner 122 has an overall one-piece seat liner design. This design is conventional because seat liner designs are typically made with the end product in mind. Subsequent variations are then incorporated to support the relevant manufacturing processes.

[0316] Now for reference Figure 8 A portion of the seat cushion 122 is partially shown as being detached from the seat assembly 120. The seat cushion 122 is formed from multiple strands 128 or three-dimensional filament loops of extruded expanded thermoplastic resin or polymer. The seat cushion 122 also has a base layer 130 formed therefrom, which is bonded to and / or integrally formed with the multiple strands 128. The extruded mesh cushion 122 is readily manufactured to have a rectangular cross-section or a uniform thickness.

[0317] Refer again Figures 5-7 The seat cushion 122 is redesigned as three layers, sections, or cushion segments 130, 132, and 134. Cushion segments 130, 132, and 134 are stacked together on top of each other to collectively provide the seat cushion 122. Segments 130, 132, and 134 are each designed to have a common maximum thickness, allowing them to be integrally formed as a sheet of extruded wire 128 and subsequently stacked. Additionally, segments 130, 132, and 134 can be pivotally interconnected to stack on top of each other. (Reference) Figure 7 The outer parallelogram of the central segment 132 is designed to pivot upwards and mate with the lateral outer surface of the upper segment 134.

[0318] Figure 9 A side view of a portion of a liner 136 according to an embodiment is shown. The liner 136 includes a pair of liner segments 138, 140, which are integrally formed into a monolithic web 128 of extruded thermoplastic resin. A pair of recesses 142 are formed in the surface of a form to define hinges 144 pivotally connecting the liner segments 138, 140. Figure 10 As shown, the padding segments 138 and 140 can pivot about the hinge 144. Any number of recesses 142 and any pivot range can be used to pivot and / or stack the padding segments 138.

[0319] Figure 11 A partially disassembled seat backrest pad 124 is shown. The seat backrest pad 124 is formed from a monolithic sheet of extruded thermoplastic mesh 128 with uniform thickness. The seat backrest pad 124 is shown after a secondary forming operation (e.g., cutting to incorporate various padding details). The cutting operation is performed automatically using methods such as waterjet cutting, laser cutting, die cutting, etc. The seat backrest pad 124 includes three padding segments 146, 148, and 150.

[0320] The central section 146 is the forward-facing section of the seat back cushion 124. The upper section 148 is the rearward-facing section and is pivotally connected to the central section 146 along the hinge 152. The lower section 150 is also the rearward-facing section and is pivotally connected to the central section 146 along the hinge 154 spaced apart from the upper hinge 152.

[0321] Figure 12 The rear side of the liner 124 in its unfolded orientation is shown. The exposed surface on the rear side is generally flat to facilitate the mating surfaces of segments 146, 148, and 150. Figures 12 to 13 As shown, the lower segment 150 pivots around the hinge 154 and stacks flat on the rear surface of the central segment 146. From Figures 13 to 14 As shown, the upper segment 148 pivots around the hinge 152 and stacks flat on the rear surface of the central segment 146.

[0322] Then, segments 146, 148, and 150 can be fixed together by hot riveting, welding, adhesives, fasteners, hook and loop fasteners, retainers, etc. Figure 14 The rear surface of the assembled seat backrest pad 124 is shown. These segments collectively form a structure for attachment to the seat backrest frame 158. Figure 4 ) groove 156. Figure 15 The front surface of the assembled seat back pad 124 is shown.

[0323] The firmness and / or conformability of each seat cushion 122, 124 are designed by the number of segments, material, 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. Seat cushions 122, 124 can be attached directly to the seat frame, or they can be attached to a foam support layer, a polyurethane carrier, or any other seat support member.

[0324] Figure 16 A gasket 160 according to another embodiment is shown. Similar to the previous embodiment, the gasket 160 includes a plurality of integrally formed and pivotally interconnected segments 162, 164, 166. A fastener 168 is disposed along a seam between two segments 162, 164. The fastener 168 may be a heat-riveted component, a welded component, an adhesive, a hook-and-loop fastener, a retainer, etc.

[0325] Seat supports (e.g., 122, 124, and / or 136) are described, which may be seat bottom pads, seat back pads, headrests, headrests, cushions, areas, and / or portions. Seat supports (e.g., 122, 124, and / or 136) include extruded thermoplastic resin mesh (which may be an extruded thermoplastic resin mesh of extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, wherein two loops are attached to each other in multiple fused connections, and the extruded thermoplastic resin mesh independently comprises 60% to 95% air by volume, with a density of about 0.01 g / cm³). 3 Up to 0.200 g / cm 3 Multiple layers (e.g., 130, 132, 134, 138 and / or 140), segments, sections, bases and / or cushions are used for mounting to a seat frame and supporting an occupant on the seat frame, which may be 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 each other and can be attached using: retaining clips (the retaining clips having an end embedded in foam and a retaining clip end attached to a plastic mesh base), hook-and-loop connector strips, hook layers, loop layers, adhesives, clamp rings, single-sided or double-sided retaining clips, bonding, welding, stitching, fastening, adhesion, thermal riveting and / or retention.

[0326] In some embodiments, at least one of the plurality of stacked layers (e.g., 130, 132, 134, 138 and / or 140) has a substantially uniform thickness, and the at least one stacked layer may have a rectangular cross-section, a uniform thickness and / or a parallelogram shape.

[0327] In some embodiments, each of the plurality of stacked layers (e.g., 130, 132, 134, 138 and / or 140) has a substantially uniform thickness.

[0328] In some embodiments, the seat support (e.g., 122, 124 and / or 136) further includes at least two stacked layers (e.g., 130, 132, 134, 138 and / or 140).

[0329] In some embodiments, each of the plurality of stacked layers (e.g., 162, 164 and / or 166) is pivotally connected to each other.

[0330] In some embodiments, at least one recess is formed in one of a plurality of stacked layers (e.g., 162, 164, 166) to provide a pivoting connection.

[0331] In some embodiments, each of the plurality of stacked layers (e.g., 162, 164, 166) is formed integrally or uniformly.

[0332] A seating assembly (e.g., 120) is described, which may be a vehicle seat, office chair, personal chair, and / or the like. The seating assembly (e.g., 120) includes a seat frame and seat supports (e.g., 122, 124, and / or 136) attached to the seat frame.

[0333] Seat support components (e.g., 122, 124, and / or 136) are described, which may be seat bottom padding, seat back padding, headrest, headrest, cushion, area, and / or portion. Seat support components (e.g., 122, 124, and / or 136) include multiple layers (e.g., 130, 132, 134, 138, and / or 140), segments, portions, bases, and / or cushions for mounting to a seat frame and supporting an occupant on the seat frame, which may be stamped steel alloy, fiber-reinforced polymer, or any suitable structural material, wire suspension pads, base plates, and / or panels. Multiple layers (e.g., 130, 132, 134, 138, and / or 140) are stacked on top of each other and can be attached using: retaining clips (the retaining clips having an end embedded in foam and a retaining clip end attached to a plastic mesh base), hook-and-loop connector strips, hook layers, loop layers, adhesives, clamp rings, single-sided or double-sided retaining clips, bonding, welding, stitching, fastening, adhesion, thermal riveting, and / or retention. 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 uniform thickness, and / or a parallelogram shape. Each of the multiple stacked layers is formed integrally and / or monolithically. Each of the multiple stacked layers (e.g., 162, 164, and / or 166) is pivotally connected to each other.

[0334] Figure 16B Method 1600 according to some embodiments is illustrated. Method 1600 is used to manufacture a pad (e.g., pads 122, 124, 130, 132, 134, 138 and / or 140), which may be a seat bottom pad, a seat back pad, a headrest, a headrest, a cushion, an area and / or a portion thereof. In various examples, method 1600 may have more or fewer steps than described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0335] A method 1600 for manufacturing a product is described, which may be a seat bottom liner, a seat back liner, a headrest, a headrest, a cushion, an area, and / or a portion thereof. Method 1600 includes a plurality of fused joints formed by extruding a thermoplastic resin web (which may be an extruded thermoplastic resin web of an extruded expanded thermoplastic resin or polymer), strands, three-dimensional loops, and / or two of the loops being attached to each other, and the extruded thermoplastic resin web independently includes 60% to 95% air by volume, with a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 (1602) Form multiple pad segments (e.g., 130, 132, 134, 138 and / or 140), and stack (1604) multiple pad segments (e.g., 130, 132, 134, 138 and / or 140) as pads (e.g., pads 122, 124 and / or 160).

[0336] In some embodiments, method 1600 includes shaping a plurality of pad segments (e.g., 130, 132, 134, 138 and / or 140) by cutting, die-cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automation.

[0337] In some embodiments, method 1600 includes forming a plurality of pad segments (e.g., 162, 164, 166) into a single sheet.

[0338] In some embodiments, method 1600 includes folding the padding segments (e.g., 162, 164, 166) to stack the padding segments on top of each other.

[0339] In some embodiments, method 1600 includes forming at least one recess in at least one of a plurality of pad segments (e.g., 162, 164, 166) to fold the pad segment.

[0340] In some embodiments, method 1600 includes cutting a plurality of pad segments (e.g., 146, 148, 150) to form a plurality of pad segments, the forming of which may include die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automation.

[0341] A seat support is described, which may be a seat bottom pad, seat back pad, headrest, headrest, cushion, area, and / or portion thereof. The seat support is manufactured using any of the foregoing or subsequent technologies.

[0342] In some embodiments, method 1600 includes mounting the product to a seat frame, which may be a stamped steel alloy, fiber-reinforced polymer or any suitable structural material, wire suspension pad, substrate and / or panel.

[0343] A seating assembly is described, which may be a vehicle seat, office chair, personal chair, and / or the like. The seating assembly is manufactured by any of the methods described above or below.

[0344] 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 conjunction with one or more methods 400, 1650, 1680, 2700, 3800.

[0345] Figure 16C Method 1650 according to some embodiments is illustrated. Method 1650 is used to manufacture a pad (e.g., pads 122, 124, 130, 132, 134, 138 and / or 140), which may be a seat bottom pad, a seat back pad, a headrest, a headrest, a cushion, an area and / or a portion thereof. In various examples, method 1650 may have more or fewer steps than described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0346] Method 1650 is used to design seat cushions, which may be seat bottom cushions, seat back cushions, headrests, headrests, pads, areas and / or sections. Method 1650 includes obtaining (1652) a design of a monolithic seat cushion (e.g., monolithic seat cushion 122) and redesigning (1654) the monolithic seat cushion design into multiple stacked cushion segment designs (e.g., 130, 132 and / or 134), layers, sections, bases and / or pads.

[0347] In some embodiments, method 1650 includes redesigning the monolithic seat cushion design into a design of multiple stacked cushion segments, each having a common maximum thickness.

[0348] 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 conjunction with methods 400, 1600, 1680, 2700, and 3800.

[0349] Figure 16D Method 1680 according to some embodiments is illustrated. Method 1680 is used to manufacture seat cushions (e.g., cushions 122, 124, 130, 132, 134, 138 and / or 140), which may be seat bottom cushions, seat back cushions, headrests, headrests, pads, areas and / or portions. In various examples, method 1680 may have more or fewer steps than described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0350] Method 1680 includes designing a plurality of gasket segments according to any of the foregoing or subsequent designs (1682) and forming (1684) a plurality of gasket segments from an extruded thermoplastic resin web, which may be an extruded thermoplastic resin web of an extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, and / or a plurality of fused joints 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 / cm³. 3 Up to 0.200 g / cm 3 .

[0351] In some embodiments, method 1680 includes stacking a plurality of padding segments as padding, which may be a seat bottom padding, a seat back padding, a headrest, a headrest, a cushion, an area and / or a portion thereof.

[0352] 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 conjunction with one or more methods 400, 1600, 1650, 2700, 3800.

[0353] refer to Figure 17 The image provides a perspective view of a vehicle seat 210 having an extruded plastic mesh base plastic with mesh cushions. The vehicle seat 210 includes a seat back 212 and a seat bottom 214. The seat back 212 includes a right seat back cushion 216 and a left seat back cushion 218. The seat bottom 214 includes a right seat bottom cushion 220 and a left seat bottom cushion 222.

[0354] Figure 18A and Figure 18BA cross-section of a seat support member serving as a vehicle seat cushion component 230 is depicted. Advantageously, the vehicle seat cushion component 230 may be part of a vehicle seat backrest 212 or a vehicle seat bottom 214. The vehicle seat component 230 includes a layer serving as a plastic mesh base 232. The plastic mesh base 232 has a first edge 234, a second edge 236, a first surface 238, and a second surface 240. A first plastic mesh cushion 242 is another layer attached to the plastic mesh base 232 at the first edge 234. A second plastic mesh cushion 244 is another layer attached to the plastic mesh base 232 at the second edge 236. The first plastic mesh cushion 242 includes a first plurality of three-dimensional loops 250 or filaments made of a first thermoplastic resin or polymer. The second plastic mesh cushion 244 includes a second plurality of three-dimensional loops 252 or filaments made of a second thermoplastic polymer. The first plurality of three-dimensional loops 250 and the second plurality of three-dimensional loops 252 are each independently shaped to fit into the form of vehicle seat cushions 242, 244. Dashed lines surrounding these components highlight the shapes of these cushion components. Similarly, the plastic mesh base 232 includes a third plurality of three-dimensional loops 254 made of a third thermoplastic polymer. The third plurality of three-dimensional loops 254 are shaped into a generally block shape or any shape suitable for use as a padding. Figure 18A An improved design is described in which a first plastic mesh pad 242 is attached to a first edge 234 and a second plastic mesh pad 244 is attached to a second edge 236. Figure 18B An improved design is depicted in which the first plastic mesh pillow 242 and the second plastic mesh pillow 244 are each disposed above the first surface 238.

[0355] Figure 19A and Figure 19BA cross-section of another variation of the vehicle seat cushion component 230 is depicted. As described above, the vehicle seat cushion component 230 may be a portion of the vehicle seat backrest 212 or the 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 surface 238, and a second surface 240. A first plastic mesh cushion 242 is attached to the plastic mesh base 232 at the first edge 234. A second plastic mesh cushion 244 is attached to the plastic mesh base 232 at the second edge 236. The first plastic mesh cushion 242 includes a first plurality of three-dimensional loops 250 made of a first thermoplastic polymer. The second plastic mesh cushion 244 includes a second plurality of three-dimensional loops 252 made of a second thermoplastic polymer. The first plurality of three-dimensional loops 250 and the second plurality of three-dimensional loops 252 are each independently shaped to fit the vehicle seat cushions 242, 244. Dashed lines around these components highlight the shapes of these cushion components. Similarly, the plastic mesh base 232 includes a third plurality of three-dimensional loops 254 made of a third thermoplastic polymer. The third plurality of three-dimensional loops 254 are shaped into a generally block shape or any shape suitable for use as a liner. An optional skin layer 256 is disposed over and contacts a first surface 238 of the shaped plurality of three-dimensional loops 254. The vehicle seat component 230 may include one or both of skin layers 256 and 258.

[0356] refer to Figure 18A , Figure 18B , Figure 19A and Figure 19B The first plastic mesh pad 242 is attached to the plastic mesh base 232, and the second plastic mesh pad 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-sided or double-sided retaining clips, etc.

[0357] Examples of methods and properties for forming the first plurality of three-dimensional loops, the second plurality of three-dimensional loops, and the third plurality of three-dimensional loops are disclosed in U.S. Patent Nos. 10,233,073 and 9,918,559, the entire disclosure of which is incorporated herein by reference in its entirety.

[0358] refer to Figure 18A , Figure 18B , Figure 19A and Figure 19BAt least a subset of the rings in the first plurality of three-dimensional loops 250, at least a subset of the rings in the second plurality of three-dimensional loops 252, and at least a subset of the rings in the third plurality of three-dimensional loops 254 are independently non-parallel or misaligned with each other. In an improved embodiment, at least a subset of the rings in the first plurality of three-dimensional loops 250, at least a subset of the rings in the second plurality of three-dimensional loops 252, and at least a subset of the rings in the third plurality of three-dimensional loops 254 are independently randomly oriented.

[0359] In a variation, the first plastic mesh pillow 242, the second plastic mesh pillow 244, and the plastic mesh base 232 independently comprise 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 comprise at least 60%, 65%, 70%, 75%, or 80% air by volume, preferably in ascending order, and at most 95%, 93%, 90%, 85%, or 80% air by volume, preferably in ascending order. In an improvement, the first plastic mesh pillow 242, the second plastic mesh pillow 244, and the plastic mesh base 232 independently have approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density. In some improved embodiments, the multiple three-dimensional wire loops include multiple fusion joints 264 in which two loops are attached to each other.

[0360] In some variations, three-dimensional loops 250, 252, and 254, along with any optional skin layer (if present), are independently composed of a thermoplastic polymer. In some improvements, the three-dimensional loops are extruded thermoplastic polymers. 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 some improvements, the thermoplastic polymer includes linear low-density polyethylene. In some improvements, the three-dimensional loops have a fineness of 200 dtex to 10,000 dtex. In some improvements, the three-dimensional loops have a fineness of 200 dtex to 5,000 dtex. In other improvements, the three-dimensional loops have a fineness of 200 dtex to 3,000 dtex.

[0361] A vehicle seat cushion (e.g., vehicle seat cushion component 230) is described, which may be a seat bottom cushion, seat back cushion, headrest, headrest, pillow, area, and / or portion thereof. 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 and includes a first plurality of three-dimensional loops (e.g., rings 250), wherein at least a subset of the rings in the first plurality of three-dimensional loops may be parallel or aligned with each other, or may be non-parallel or misaligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex. The first plurality of three-dimensional loops are composed of a first thermoplastic polymer, which may contain 60% to 95% air by volume and have a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the first plurality of three-dimensional loops can be independently formed into the form of a vehicle seat cushion, wherein the first 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 linear low-density polyethylene. The vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a second plastic mesh cushion (e.g., second plastic mesh cushion 244), which can be formed by compression molding, including a second plurality of three-dimensional loops (e.g., rings 252), wherein at least a subset of the rings in the second plurality of three-dimensional loops can be parallel or aligned with each other, or can be non-parallel or misaligned 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 loops are composed of a second thermoplastic polymer, which can contain 60% to 95% air by volume and has a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the second plurality of three-dimensional loops can be independently formed into the form of a vehicle seat cushion, 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 linear low-density polyethylene. The vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a plastic mesh base (e.g., plastic mesh base 232), which can be an extruded thermoplastic resin mesh of an extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, or a plurality of fused joints where two loops are attached to each other. The plastic mesh base independently includes 60% to 95% air by volume, with a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3The plastic mesh substrate comprises a third plurality of three-dimensional loops (e.g., loop 254), wherein at least a subset of the loops in the third plurality of three-dimensional loops may be parallel or aligned with each other, or may be non-parallel or misaligned 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 loops are composed of a third thermoplastic polymer, which may contain 60% to 95% air by volume and have a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the third plurality of three-dimensional filament loops can be independently formed into the form of a vehicle seat cushion, wherein the third 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 linear low-density polyethylene. The plastic mesh substrate may have a block shape and has a first edge (e.g., first edge 234), a second edge (e.g., second edge 236), a first surface (e.g., first surface 238), and a second surface (e.g., second surface 240). A first plastic mesh cushion (e.g., first plastic mesh cushion 242) is attached to the plastic mesh substrate (e.g., plastic mesh substrate 232) at the first edge (e.g., first edge 234), and a second plastic mesh cushion (e.g., second plastic mesh cushion 244) is attached to the plastic mesh substrate (e.g., plastic mesh substrate 232) at the second edge (e.g., second edge 236). These attachments can be secured using retaining clips (which have an end embedded in the foam and a retaining clip end attached to the plastic mesh base), hook and loop connector strips, hook layers, loop layers, adhesives, clamp rings, single-sided or double-sided retaining clips, bonding, welding, stitching, fastening, adhesion, thermal riveting and / or other methods.

[0362] In some embodiments, a vehicle seat cushion component (e.g., vehicle seat cushion component 230) is included in a vehicle seat backrest (e.g., vehicle seat backrest 212) or a vehicle seat bottom (e.g., vehicle seat bottom 214).

[0363] In some embodiments, the first plurality of three-dimensional wire loops (e.g., loop 250), the second plurality of three-dimensional wire loops (e.g., loop 252), and the third plurality of three-dimensional wire loops each independently include a plurality of fusion joints in which two of the loops are attached to each other.

[0364] In some embodiments, a first plurality of three-dimensional loops (e.g., loop 250) and a second plurality of three-dimensional loops (e.g., loop 252) are each independently shaped into the form of a vehicle seat cushion.

[0365] In some embodiments, a first plastic mesh pillow (e.g., a first plastic mesh pillow 242) and a second plastic mesh pillow are each disposed above the first surface.

[0366] In some embodiments, a first plastic mesh pillow (e.g., first plastic mesh pillow 242) is attached to a first edge, and a second plastic mesh pillow is attached to a second edge.

[0367] In some embodiments, the first plastic mesh pad pillow (e.g., the first plastic mesh pad pillow 242) and the second plastic mesh pad pillow are attached to the plastic mesh base (e.g., the plastic mesh base 232) by hook and loop strips, adhesives, retaining clips and / or clamping rings.

[0368] In some embodiments, at least a subset of the rings in a first plurality of three-dimensional loops (e.g., loop 250), at least a subset of the rings in a second plurality of three-dimensional loops (e.g., loop 252), and at least a subset of the rings in a third plurality of three-dimensional loops are not parallel or aligned with each other.

[0369] In some embodiments, at least a subset of the rings in a first plurality of three-dimensional loops (e.g., loop 250), at least a subset of the rings in a second plurality of three-dimensional loops (e.g., loop 252), and at least a subset of the rings in a third plurality of three-dimensional loops are randomly oriented.

[0370] In some embodiments, the first skin layer is disposed over a first side of the plastic mesh substrate (e.g., plastic mesh substrate 232).

[0371] In some embodiments, the first skin layer is disposed over the second side of the plastic mesh substrate (e.g., plastic mesh substrate 232).

[0372] In some embodiments, the first plastic mesh pillow (e.g., first plastic mesh pillow 242), the second plastic mesh pillow, and the plastic mesh base (e.g., plastic mesh base 232) independently comprise 60% to 95% by volume air.

[0373] In some embodiments, the first plastic mesh pillow (e.g., first plastic mesh pillow 242), the second plastic mesh pillow, and the plastic mesh base independently have a density of approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0374] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extruded thermoplastic polymer.

[0375] 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.

[0376] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently linear low-density polyethylene.

[0377] In some embodiments, the first plurality of three-dimensional loops (e.g., loop 250), the second plurality of three-dimensional loops (e.g., loop 252), and the third plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex.

[0378] A vehicle seat cushion component (e.g., 230) is described. This component can be a seat bottom cushion, seat back cushion, headrest, headrest, pad, area, and / or portion. The vehicle seat cushion component (e.g., 230) includes a first plastic mesh cushion (e.g., 242), which can be formed by compression molding and includes a first plurality of three-dimensional loops (e.g., 250). At least a subset of the loops in the first plurality of three-dimensional loops can be parallel or aligned with each other, or can be non-parallel or misaligned 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 loops are composed of a first thermoplastic polymer, which can contain 60% to 95% air by volume and has a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the first plurality of three-dimensional loops can be independently formed into the form of a vehicle seat cushion, 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 linear low-density polyethylene. The vehicle seat cushion component (e.g., 230) includes a second plastic mesh cushion (e.g., 244), which can be formed by compression molding, including a second plurality of three-dimensional loops (e.g., 252), wherein at least a subset of the loops in the second plurality of three-dimensional loops can be parallel or aligned with each other, or can be non-parallel or misaligned 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 loops are composed of a second thermoplastic polymer, which can contain 60% to 95% air by volume and has a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3Each of the second plurality of three-dimensional loops can be independently formed into the form of a vehicle seat cushion, 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 linear low-density polyethylene. The vehicle seat cushion component (e.g., 230) includes a plastic mesh substrate (e.g., 232), which may be an extruded thermoplastic resin mesh of an extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, and a plurality of fused joints where two loops are attached to each other. The plastic mesh substrate independently comprises 60% to 95% air by volume and has a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The plastic mesh substrate comprises a third plurality of three-dimensional loops (e.g., 254), wherein at least a subset of the loops in the third plurality of three-dimensional loops may be parallel or aligned with each other, or may be non-parallel or misaligned 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 loops are composed of a third thermoplastic polymer, which may contain 60% to 95% air by volume and have a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the third plurality of three-dimensional filament loops can be independently shaped into the form of a vehicle seat cushion, 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 linear low-density polyethylene. A plastic mesh substrate (e.g., 232) has a first edge, a second edge, a first surface, and a second surface. A first plastic mesh cushion (e.g., 242) is attached to the plastic mesh substrate (e.g., 232) at the first edge, and a second plastic mesh cushion is attached to the plastic mesh substrate at the second edge. These attachments can be achieved using retaining clips (the retaining clips having an end embedded in foam and a retaining clip end attached to the plastic mesh substrate), hook-and-loop connector strips, hook layers, loop layers, adhesives, clamp rings, single-sided or double-sided retaining clips, bonding, welding, stitching, fastening, adhesion, thermal riveting, and / or other methods of retention. The first plurality of three-dimensional wire loops (e.g., 250), the second plurality of three-dimensional wire loops (e.g., 252), and the third plurality of three-dimensional wire loops (e.g., 254) each independently include a plurality of fused joints in which two of the loops are attached to each other.

[0379] In some embodiments, the vehicle seat cushion component (e.g., 230) is included in the vehicle seat back or the bottom of the vehicle seat.

[0380] In some embodiments, the plastic mesh substrate (e.g., 232) contains 60% to 95% air by volume.

[0381] 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.

[0382] 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 conjunction with one or more methods 400, 1600, 1650, 1680, 2700, 3800.

[0383] refer to Figure 20 This image provides a perspective view of a vehicle seat 310 with an extruded plastic mesh base. The vehicle seat 310 includes a seat back 312 and a seat bottom 314. The seat back 312 includes a right seat back cushion 316 and a left seat back cushion 318. The seat bottom 314 includes a right seat bottom cushion 320 and a left seat bottom cushion 322. The seat back 312 also includes a seat back frame 324 for mounting seat back cushion components thereon. Similarly, the seat bottom 314 includes a seat bottom frame 326 for mounting seat bottom cushion components thereon.

[0384] refer to Figure 21A and Figure 21B A schematic diagram of a vehicle seat component 330 is provided. The vehicle seat component 330 includes a first pillow assembly 332. The first pillow assembly 332 includes a first core padding portion 334, layer, or segment surrounded by a first outer pillow covering 336 of a first non-woven material. A first pillow trim covering 338 surrounds the first outer pillow covering 336. A second pillow assembly 340 includes a second core padding portion 342, layer, or segment surrounded by a second outer pillow covering 344 of a second non-woven material. A second pillow trim covering 348 surrounds the second outer pillow covering 344. A trim covering portion 350 includes a first edge 352 and a second edge 354. Characteristically, the first pillow assembly 332 is sewn to the trim covering portion at the first edge along seam 356. Similarly, the second pillow assembly 340 is sewn to the trim covering portion at the second edge along seam 358. In a variant, the vehicle seat component 330 also includes a central padding component 360 positioned in an opening 362 defined by a trim covering portion.

[0385] In the improved design, the first outer pillow cover 336 and the second outer pillow cover 344 each independently comprise 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 comprise natural fibers (e.g., jute fibers).

[0386] In a variation, the first cushion assembly 332 and the second cushion assembly 340 are each manufactured independently by compression molding. For example, a layered / sandwich assembly of jute or nonwoven material and a core padding portion can be formed by compression molding. In an improved embodiment, each cushion assembly includes a top layer of jute / nonwoven fabric, a middle padding portion, and a bottom layer of jute / nonwoven fabric.

[0387] In a variant, the decorative covering portion defines an opening 362 for receiving the central liner component 360.

[0388] In a variant, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 are each independently composed of a foamed polymer. In an improved embodiment, the first core pad portion 334 and the second core pad portion 342 are each independently composed of foamed polyurethane. As is known in the art, foamed polyurethane is formed by reacting isocyanate, polyol, and a suitable blowing agent.

[0389] In such Figure 21A and Figure 21B In another depicted variant, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 are each independently composed of a plurality of three-dimensional loops or strands made of a thermoplastic polymer or resin. In an improved embodiment, at least a subset of the loops in the plurality of three-dimensional loops are not parallel or misaligned with each other. In an improved embodiment, the loops in the plurality of three-dimensional loops are randomly oriented.

[0390] Still referencing Figure 21A and Figure 21BIn another variation, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 each independently comprise a plurality of three-dimensional loops having 60% to 95% air by volume. In some improvements, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 each independently comprise a plurality of three-dimensional loops having at least, preferably in ascending order, 60%, 65%, 70%, 75%, or 80% air by volume, and at most, preferably in ascending order, 95%, 93%, 90%, 85%, or 80% air by volume. In an improved embodiment, the first core pad portion 334, the second core pad portion 342, and the central pad component 360 independently comprise a density of approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Multiple three-dimensional wire loops. In some improvements, the multiple three-dimensional wire loops include multiple fusion joints 364 in which two loops are attached to each other.

[0391] In this improved embodiment, the three-dimensional filament ring 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 this improved embodiment, the thermoplastic polymer includes linear low-density polyethylene. In another improved embodiment, the thermoplastic polymer is a biodegradable or recyclable polymer (e.g., a "green" polymer).

[0392] In some improved versions, the three-dimensional wire loop has a fineness ranging from 200 dtex to 10,000 dtex. In another improved version, the three-dimensional wire loop has a fineness ranging from 200 dtex to 5,000 dtex. In yet another improved version, the three-dimensional wire loop has a fineness ranging from 200 dtex to 3,000 dtex.

[0393] Examples of methods and properties for forming multiple three-dimensional filament loops are disclosed in U.S. Patent Nos. 10,233,073 and 9,918,559, the entire disclosure of which is incorporated herein by reference in its entirety.

[0394] Advantageously, the aforementioned vehicle seat cushion component 330 improves the sustainability of current automotive seat components and provides occupant support, enhancing the feel and damping qualities (related to sound and energy) of the extruded plastic mesh assembly. Specifically, the vehicle seat cushion component 330 provides sound insulation for any stiff, brittle mesh material that can be added to the assembly, allows for aggressive contouring and shape of the A-side features, and allows for layered densities (the top and bottom can have different densities depending on temperature), temperature buffering (insulating properties), and a consistent feel.

[0395] refer to Figure 20 , Figure 21A and Figure 21B A vehicle seat 310 is provided, including the aforementioned vehicle seat cushion component 330. 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 described above, the vehicle seat cushion component 330 includes a first pillow assembly 332. The first pillow assembly 332 includes a first core cushion portion 334 surrounded by a first outer pillow cover 336 of a first nonwoven material. A first pillow trim cover 338 surrounds the first outer pillow cover 336. A second pillow assembly 340 includes a second core cushion portion 342 surrounded by a second outer pillow cover 344 of a second nonwoven material. A second pillow trim cover 348 surrounds the second outer pillow cover 344. The decorative cover portion 350 includes a first edge 352 and a second edge 354. Characteristically, a first cushion assembly 332 is sewn to the decorative cover portion at the first edge 352 along a seam 356. Similarly, a second cushion assembly 340 is sewn to the decorative cover portion at the second edge 354 along a seam 358. In a variant, the vehicle seat component 330 also includes a central padding component 360 positioned within an opening 362 defined by the decorative cover portion 350.

[0396] A vehicle seat cushion component (e.g., 330) is described, which may be a seat bottom cushion, seat back cushion, headrest, headrest, pillow, area, and / or portion. The vehicle seat cushion component (e.g., 330) includes: a first pillow assembly (e.g., 332), which can be formed by compression molding, and includes a first core pad portion (e.g., 334), which may be foamed polyurethane, a plurality of three-dimensional loops made of a thermoplastic polymer, the first core pad portion having 60% to 95% air by volume and a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The first core padding portion is surrounded by a first outer pillow cover (e.g., 336), which may be a non-woven fabric, natural fiber, and / or jute fiber. The first outer pillow cover is surrounded by a first pillow decorative cover (e.g., 338), which may be a non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl, and / or other materials. A second pillow assembly (e.g., 340) may be formed by compression molding and includes a second core padding portion (e.g., 342), which may be foamed polyurethane, a plurality of three-dimensional loops composed of a thermoplastic polymer, and contains 60% to 95% air by volume and has a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The second core padding portion is surrounded by a second outer pillow cover (e.g., 344), which may be a non-woven fabric, natural fiber, and / or jute fiber; and a decorative cover portion (e.g., 350), which may be a non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other material, the decorative cover portion having a first edge and a second edge, a first pillow assembly (e.g., 332) being sewn to the decorative cover portion (e.g., 350) at the first edge, and a second pillow assembly (e.g., 340) being sewn to the decorative cover portion (e.g., 350) at the second edge.

[0397] In some embodiments, the vehicle seat cushion component (e.g., 330) is included in the vehicle seat back or the bottom of the vehicle seat.

[0398] 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 nonwoven material and core padding portion, a top jute / nonwoven fabric, an intermediate padding portion and a bottom jute / nonwoven fabric.

[0399] In some embodiments, the first outer pillow cover (e.g., 336) and the second outer pillow cover (e.g., 344) each independently comprise a nonwoven fabric.

[0400] In some embodiments, the first outer pillow cover (e.g., 336) and the second outer pillow cover (e.g., 344) each independently comprise natural fibers.

[0401] In some embodiments, the vehicle seat cushion component (e.g., 330) further includes a central cushion component (e.g., 360), which may be foamed polyurethane, a plurality of three-dimensional loops made of a thermoplastic polymer, the central cushion component having 60% to 95% air by volume, and / or a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The central liner component is positioned in an opening defined by the decorative covering portion.

[0402] In some embodiments, the first core pad portion (e.g., 334), the second core pad portion (e.g., 342), and the central pad portion (e.g., 360) are each independently composed of foamed polyurethane (such as isocyanate, polyol, and suitable foaming agent).

[0403] 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 loops, which may be multiple fused joints in which two loops are attached to each other. The plurality of three-dimensional loops may be non-parallel or misaligned with each other. The plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex and 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.

[0404] In some embodiments, the plurality of three-dimensional wire loops include a plurality of fusion joints in which two loops are attached to each other.

[0405] In some embodiments, at least a subset of the loops in the plurality of three-dimensional loops are not parallel or aligned with each other.

[0406] In some embodiments, the first core pad portion (e.g., 334), the second core pad portion (e.g., 342), and the central pad portion (e.g., 360) independently have 60% to 95% air by volume.

[0407] 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) each independently have approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0408] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0409] In some embodiments, the thermoplastic polymer includes components selected from the group consisting of: polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0410] In some embodiments, the thermoplastic polymer is a biodegradable or recyclable polymer.

[0411] In some embodiments, the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0412] In some embodiments, the vehicle seat cushion component (e.g., 330) includes components that provide sound insulation and temperature cushioning.

[0413] A vehicle seat (e.g., 310) is disclosed, which may be a vehicle seat, office chair, personal chair, and / or the like. The vehicle seat (e.g., 310) includes: a seat base having a seat base frame, which may be a stamped steel alloy, fiber-reinforced polymer, or any suitable structural material, wire suspension pads, a substrate, and / or a panel; a seat back attached to the seat base, the seat back including a seat back frame, which may be a stamped steel alloy, fiber-reinforced polymer, or any suitable structural material, wire suspension pads, a substrate, and / or a panel; and a vehicle seat cushion component (e.g., 330), which may be... Seat bottom padding, seat back padding, headrest, headrest, cushion, area and / or portion attached to the seat bottom frame and / or seat back frame; vehicle seat padding component (e.g., 330) includes: a first cushion assembly (e.g., 332), which can be formed by compression molding and includes a first core padding portion (e.g., 334), which may be foamed polyurethane, a plurality of three-dimensional loops made of thermoplastic polymer, and has 60% to 95% air by volume and a density of 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The first core padding portion is surrounded by a first outer pillow cover (e.g., 336), which may be a non-woven fabric, natural fiber, and / or jute fiber. The first outer pillow cover is surrounded by a first pillow decorative cover (e.g., 338), which may be a non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other materials. A second pillow assembly (e.g., 340) may be formed by compression molding and includes a second core padding portion (e.g., 342), which may be foamed polyurethane, a plurality of three-dimensional loops composed of a thermoplastic polymer, and contains 60% to 95% air by volume with a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3The second core padding portion is surrounded by a second outer pillow cover (e.g., 344), which may be a non-woven fabric, natural fiber, and / or jute fiber. The second outer pillow cover is surrounded by a second pillow decorative cover, which may be a non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other materials. The decorative cover portion may be a non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other materials. The decorative cover portion has a first edge and a second edge. A first pillow assembly (e.g., 332) is sewn to the decorative cover portion at the first edge, and a second pillow assembly (e.g., 340) is sewn to the decorative cover portion at the second edge.

[0414] In some embodiments, the first outer pillow cover (e.g., 336) and the second outer pillow cover (e.g., 344) each independently comprise a nonwoven fabric.

[0415] In some embodiments, the first outer pillow cover (e.g., 336) and the second outer pillow cover (e.g., 344) each independently comprise natural fibers.

[0416] In some embodiments, the vehicle seat cushion component (e.g., 330) further includes a central cushion component (e.g., 360), which may be foamed polyurethane, a plurality of three-dimensional loops made of a thermoplastic polymer, and has 60% to 95% air by volume and / or a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The central liner component is positioned in an opening defined by the decorative covering portion.

[0417] In some embodiments, the first core pad portion (e.g., 334), the second core pad portion (e.g., 342), and the central pad portion (e.g., 360) are each independently composed of foamed polyurethane (such as isocyanate, polyol, and suitable foaming agent).

[0418] 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 loops, which may be multiple fused joints in which two loops are attached to each other. The plurality of three-dimensional loops may be non-parallel or misaligned with each other. The plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex and 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.

[0419] In some embodiments, the plurality of three-dimensional wire loops include a plurality of fusion joints in which two loops are attached to each other.

[0420] In some embodiments, at least a subset of the loops in the plurality of three-dimensional loops are not parallel or aligned with each other.

[0421] In some embodiments, the first core liner portion (e.g., 334) and the second core liner portion (e.g., 342) contain 60% to 95% air by volume.

[0422] In some embodiments, the first core pad portion (e.g., 334) and the second core pad portion (e.g., 342) each independently have approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0423] In some embodiments, the thermoplastic polymer is an extruded 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.

[0424] 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 conjunction with one or more methods 400, 1600, 1650, 1680, 2700, 3800.

[0425] refer to Figure 22 The image provides a perspective view of a vehicle seat 410 with an extruded plastic mesh base. The vehicle seat 410 includes a seat back 412 and a seat bottom 414. The seat back 412 includes a right seat back cushion 416 and a left seat back cushion 418. The seat bottom 414 includes a right seat bottom cushion 420 and a left seat bottom cushion 422.

[0426] Figure 23A and Figure 23B A cross-section of a vehicle seat component 430 is depicted. Advantageously, the vehicle seat component 430 is a vehicle seat backrest or a vehicle seat bottom. The vehicle seat component 430 includes a plastic mesh base 432. The plastic mesh base 432 comprises a plurality of shaped three-dimensional loops 434 or strands made of a thermoplastic polymer or resin. In this case, the plurality of three-dimensional loops 434 have a generally blocky shape or any shape suitable for use as a pad. The plastic mesh base 432 has a first edge 442, a second edge 444, a first surface 446, and a second surface 448. A first foam pad 450 is attached to the plastic mesh base at the first edge 442. A second foam pad 452 is attached to the plastic mesh base 432 at the second edge 444. Figure 23A An improved design is described in which the first foam pad 450 is attached to the first edge 442 and the second foam pad 452 is attached to the second edge 444. Figure 23B An improved design is described in which the first foamed pillow 450 and the second foamed pillow 452 are each disposed above the first surface 446.

[0427] Figure 24A and Figure 24B A cross-section of another variation of the cushioning portion of a vehicle seat is depicted. As described above, vehicle seat component 430 is a vehicle seat backrest or vehicle seat bottom. Vehicle seat component 430 includes a plastic mesh base 432. The plastic mesh base 432 includes a plurality of shaped three-dimensional loops 434 or strands made of a thermoplastic polymer or resin. The plastic mesh base 432 has a first edge 442, a second edge 444, a first surface 446, and a second surface 448. A first foam pad 450 is attached to the plastic mesh base 432 at the first edge 442. A second foam pad 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 surface 446 of the shaped plurality of three-dimensional loops 434. An optional skin layer 458 is disposed on and contacts the second surface 448 of the shaped plurality of three-dimensional loops 434. The vehicle seat component 430 may include one or both of skin layers 456 and 458.

[0428] refer to Figure 23A , Figure 23B , Figure 24A and Figure 24B The first foamed pillow 450 and the second foamed pillow 452 are each independently composed of a foaming polymer. In an improved embodiment, the first foamed pillow 450 and the second foamed pillow 452 are each independently composed of foamed polyurethane. As is known in the art, foamed polyurethane is formed by reacting isocyanate, polyol and suitable foaming agent.

[0429] refer to Figure 23A , Figure 23B , Figure 24A and Figure 24B A first foamed pillow 450 is attached to a plastic mesh base 432 using a first retaining clip 460, and a second foamed pillow 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. An example of a retaining clip is disclosed in U.S. Patent Application No. 17 / 724,866, the entire disclosure of which is incorporated herein by reference.

[0430] Examples of methods for forming and properties of multiple three-dimensional filament loops are disclosed in U.S. Patent Nos. 10,233,073 and 9,918,559, the entire disclosure of which is incorporated herein by reference in its entirety.

[0431] refer to Figure 23A , Figure 23B , Figure 24A and Figure 24B In the improved design, at least a subset of the loops in the plurality of three-dimensional wire loops are not parallel or misaligned with each other. In the improved design, the loops in the plurality of three-dimensional wire loops are randomly oriented, and the plastic mesh substrate contains 60% to 95% air by volume. In the improved design, the plastic mesh substrate has approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density. In some improved embodiments, the multiple three-dimensional wire loops include multiple fusion joints 464 in which two loops are attached to each other.

[0432] In some variations, the three-dimensional filaments and an optional skin layer (if present) are composed of a thermoplastic polymer. In some improvements, the three-dimensional filaments are extruded thermoplastic polymers. 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 some improvements, the thermoplastic polymer includes linear low-density polyethylene. In some improvements, the three-dimensional filaments have a fineness of 200 dtex to 10,000 dtex. In some improvements, the three-dimensional filaments have a fineness of 200 dtex to 5,000 dtex. In other improvements, the three-dimensional filaments have a fineness of 200 dtex to 3,000 dtex.

[0433] A vehicle seat cushion component (e.g., 430) is described. This component can be a seat bottom cushion, seat back cushion, headrest, headrest, pillow, area, and / or 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, strands, three-dimensional loops, or a plurality of fused joints where two loops are attached to each other. The plastic mesh substrate independently comprises 60% to 95% air by volume and has a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The plastic mesh substrate (e.g., 432) comprises a plurality of three-dimensional loops, wherein at least a subset of the loops may be parallel or aligned with each other, or may be non-parallel or misaligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex. The three-dimensional loops are composed of a thermoplastic polymer and may contain 60% to 95% air by volume, with a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the three-dimensional filament loops can be independently shaped into a form suitable for vehicle seat cushions or pillows. 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 linear low-density polyethylene. The plastic mesh substrate (e.g., 432) has a first edge, a second edge, a first surface that may be a skin layer, and a second surface that may be a skin layer. A vehicle seat cushion component (e.g., 430) includes a first foamed cushion (e.g., 450) and a second foamed cushion (e.g., 452). The first foamed cushion may be a foaming polymer, foamed polyurethane, isocyanate, polyol, and / or a suitable foaming agent. The first foamed cushion is attached to a plastic mesh base (e.g., 432) at a first edge. This attachment may or may not utilize a retaining clip (the retaining clip having an end embedded in the foam and a retaining clip end attached to the plastic mesh base), hook-and-loop connector strip, hook layer, loop layer, adhesive, clamp ring, single-sided or double-sided retaining clip, bonding, welding, stitching, fastening, adhesion, thermal riveting, and / or other means of retention. The second foamed cushion may be a foaming polymer, foamed polyurethane, isocyanate, polyol, and / or a suitable foaming agent. The second foamed cushion is attached to the plastic mesh base (e.g., 432) at a second edge.

[0434] In some embodiments, the vehicle seat cushion component (e.g., 430) is included in the vehicle seat back or the bottom of the vehicle seat.

[0435] In some embodiments, the plurality of three-dimensional loops include a plurality of fusion joints in which two loops are attached to each other, and the two loops may be parallel or aligned with each other, or may be non-parallel or misaligned with each other, and / or randomly oriented.

[0436] In some embodiments, the first foamed pillow (e.g., 450) and the second foamed pillow (e.g., 452) are each independently composed of a foaming polymer, which may be foamed polyurethane.

[0437] In some embodiments, the first foamed pillow (e.g., 450) and the second foamed pillow (e.g., 452) are each independently composed of foamed polyurethane, which may be a foaming polymer, isocyanate, polyol and / or a suitable foaming agent.

[0438] In some embodiments, the first foamed pillow (e.g., 450) and the second foamed pillow (e.g., 452) are each at least partially disposed above the first surface.

[0439] In some embodiments, a first foam pad (e.g., 450) is attached to a first edge, and a second foam pad (e.g., 452) is attached to a second edge.

[0440] In some embodiments, a first foamed pillow (e.g., 450) is attached to a plastic mesh substrate (e.g., 432) using a first retaining clip, and a second foamed pillow (e.g., 452) is attached to the plastic mesh substrate (e.g., 432) using a second retaining clip. The first and second retaining clips each have an end embedded in the foam of the respective first or second foamed pillow (e.g., 452) and a retaining clip end attached to the plastic mesh substrate (e.g., 432).

[0441] In some embodiments, at least a subset of the loops in the plurality of three-dimensional loops are not parallel or aligned with each other.

[0442] In some embodiments, the loops in the plurality of three-dimensional wire loops are randomly oriented.

[0443] In some embodiments, the plastic mesh substrate (e.g., 432) contains 60% to 95% air by volume.

[0444] In some embodiments, the plastic mesh substrate (e.g., 432) has a density of approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0445] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0446] In some embodiments, the thermoplastic polymer includes components 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] In some embodiments, the thermoplastic polymer includes linear low-density polyethylene.

[0448] In some embodiments, the plurality of three-dimensional wire loops have a fineness of 200 dtex to 10,000 dtex.

[0449] Disclosed are vehicle seat cushion components (e.g., 430), which may be seat bottom cushions, seat back cushions, headrests, headrests, pillows, areas, and / or portions thereof. The vehicle seat cushion component includes a plastic mesh substrate (e.g., 432), which may be an extruded thermoplastic resin mesh, strands, three-dimensional loops, or a plurality of fused joints where two loops are attached to each other. The plastic mesh substrate independently comprises 60% to 95% air by volume, and the density of the plastic mesh substrate is 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The plastic mesh substrate (e.g., 432) comprises a plurality of three-dimensional loops, wherein at least a subset of the loops in the plurality of three-dimensional loops may be parallel or aligned with each other, or may be non-parallel or misaligned with each other, may be randomly oriented, and may have a fineness of 200 dtex to 10,000 dtex. The three-dimensional loops are composed of a thermoplastic polymer and may contain 60% to 95% air by volume, with a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Each of the three-dimensional filament rings can be independently formed into the form of a seat cushion for a vehicle, 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 linear low-density polyethylene.

[0450] In some embodiments, the vehicle seat cushion component (e.g., 430) is included in the vehicle seat back or the bottom of the vehicle seat.

[0451] In some embodiments, the plurality of three-dimensional wire loops include a plurality of fusion joints in which two loops are attached to each other.

[0452] In some embodiments, the rings in the plurality of three-dimensional wire loops are randomly oriented.

[0453] In some embodiments, the plastic mesh substrate (e.g., 432) contains 60% to 95% air by volume.

[0454] In some embodiments, the thermoplastic polymer includes components selected from the group consisting of: polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0455] 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 conjunction with another method 400, 1600, 1650, 1680, 2700, 3800.

[0456] Figure 25 A seat assembly 520 according to an embodiment is shown. The seat assembly 520 is depicted as a vehicle seat and can be used as a seat assembly in land vehicles, aircraft, ships, etc. The seat assembly 520 can be used as an individual chair or bench chair in any row within a vehicle. Alternatively, the seat assembly 520 can also be used as an office chair or any other type of chair. The seat assembly 520 omits conventional foam to improve support and comfort. The seat assembly 520 may also optionally employ recyclable materials manufactured for further recycling at the end of its use.

[0457] Seat assembly 520 includes a seat base 522 sized to receive a seated occupant and support the occupant's pelvis and thighs. Seat assembly 520 also includes a seat back 524 sized to extend upright from the seat base 522 to support the occupant's back. A headrest (or headrest) 526 may also be supported on and above the seat back 524 to support the occupant's head. The seat base 522 is adapted to be supported by an underlying support surface. In the depicted embodiment, seat assembly 520 includes a pair of rails 528 for mounting the seat base 522 to a vehicle floor for fore-and-aft adjustment relative to the vehicle floor. The seat back 524 may also be adjustable to tilt relative to the seat base 522. While in the depicted embodiment, the headrest 526 is shown integrated with and integral with the seat back 524, in some embodiments, the headrest 526 may be separate and therefore adjustable in height, tilt, and forward / rear direction. Other adjustments may be provided, as is known in the art.

[0458] The seat base 522 may include a frame (not shown) for providing rigid structural support to the seat base 522. Similarly, the seat back 524 may also include a frame (not shown) connected to the seat base frame to extend upright from the seat base 522 and provide rigid structural support to the seat back 524. In some embodiments, a single (monolithic) frame may optionally be used for both the seat base 522 and the seat back 524 to provide rigid structural support. These / such frames may optionally be formed of stamped steel alloy, fiber-reinforced polymer, or any suitable structural material.

[0459] Conventional seat assemblies comprise multiple layers of foam to collectively provide cushioning across the frame. Variations in the foam layers' density provide compliant support to the occupant while distributing forces from the occupant to the frame. The foam layers also contribute to occupant comfort. However, some foam-free materials have been found to improve support, comfort, performance, and compactness, while also facilitating the potential recycling of materials at the end of the seat assembly's lifespan. Therefore, this disclosure relates to providing cushioning across the frame using foam-free materials.

[0460] Still referencing Figure 25 The seat assembly 520 may optionally include one or more seat bottom pads 522 and one or more seat back pads 532. One or more seat bottom pads 530, one or more seat back pads 532, or both may comprise a foam-free material. In some embodiments, the foam-free material of one or more seat bottom pads 530, one or more seat back pads 532, or both may optionally be one or more stranded mesh materials.

[0461] Now for reference Figure 26One of the seat bottom pads 530 is shown partially detached from the seat assembly 520. The seat bottom pad 530 may, but does not necessarily, be the same as one or more seat back pads 532, and may be formed from a plurality of strands 534 or loops of extruded expanded thermoplastic resin. In some embodiments, the seat bottom pad 530 may also optionally be 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 bonded to multiple strands 534 during thermoplastic resin curing or via other joining methods such as compression molding, adhesives, mechanical fasteners (e.g., clamps, clamp rings, angled ribbed shank fasteners (also known as Christmas tree fasteners), hook and loop fasteners, etc.), stitching, etc. In some embodiments, layer 536 may also be an extruded thermoplastic resin material, a nonwoven material, or both. In an exemplary embodiment, the nonwoven material of layer 536 may optionally include jute, which is a biodegradable plant fiber.

[0462] refer to Figure 27 Layer 536 may optionally provide surfaces for attaching other seat components 538, 540 by adhesives, mechanical fasteners (e.g., clamps, clamp rings, Christmas tree fasteners, hook and loop fasteners, etc.), or the like. In the depicted embodiment, 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 may optionally be one or more of the following: decorative covers, actuators such as airbag assemblies, heat transfer layers such as heating pads, etc.

[0463] In the depicted embodiment, the clamping rings 542 attached to the compression-molded jute 536 and the expanded thermoplastic resin mesh 534 provide a suitable tensile-resistant attachment. For example, this embodiment can withstand tensile loads of at least 50 Newtons and up to 151 Newtons, with deformations of at least 26 mm and up to 44 mm.

[0464] Therefore, this document discloses a seat assembly including a seat bottom, a seat back, and a seat trim assembly, wherein the seat trim assembly may optionally be 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, the at least one fabric being sized to displace on the surface of a cushion, and the at least one retainer being coupled to the at least one fabric along the periphery of the fabric to receive the trim element. In some embodiments, the seat trim assembly also includes a cushion, which may optionally include a twisted mesh material. Similarly, in some embodiments, the seat trim assembly also includes a trim cover sized to at least partially surround the cushion and at least one fabric, such that the trim cover is coupled to at least one retainer. The at least one retainer may be directly or indirectly coupled to the cushion, the trim element, or the trim cover.

[0465] The decorative components of the seat upholstery assembly may be actuators such as airbag assemblies, heat transfer layers such as heating pads, or any combination thereof. The retainers of the seat upholstery assembly may be one or more of at least one clamping ring, a clamping ring, a Christmas tree fastener, a hook-and-loop fastener, etc., or any combination thereof. At least one fabric of the seat upholstery assembly may be any nonwoven material, fabric, textile, or any combination thereof. In some embodiments, the nonwoven material of at least one fabric further includes jute.

[0466] In some embodiments of this disclosure, a seat assembly is disclosed, comprising a seat base, a seat back, and a product formed by a method including the following steps, wherein the product may be located in the seat base, the seat back, or both. These steps may optionally include attaching at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a pad, and attaching a trim member to at least one retainer. In some embodiments, the method further includes compressing and molding at least one fabric into the contour of a pad before stacking at least one fabric on the pad. In other embodiments, at least one fabric may be attached to the contour of the pad via an adhesive, mechanical fastener (such as a clamp, clamp ring, Christmas tree fastener, hook and loop fastener, etc.), or the like before stacking at least one fabric on the pad. At least one retainer may be directly or indirectly attached to at least one fabric. 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 pad may also optionally include stacking at least one fabric on a twisted mesh material pad.

[0467] In some embodiments, the product formed by the foregoing method further includes a decorative cover, sized to at least partially surround the padding and at least one fabric, attached to at least one retainer. In some exemplary embodiments, the decorative component of the product formed by this 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 this method may be at least one clamping ring, a clamping ring, a Christmas tree fastener, a hook and loop fastener, or any combination thereof. At least one fabric of the product formed by this method may be any nonwoven material, fabric, textile, or any combination thereof. In some exemplary embodiments, the nonwoven material of at least one fabric further includes jute.

[0468] According to other aspects of this disclosure, a decorative assembly manufactured by the following method is disclosed. The method includes attaching at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a pad, and attaching a decorative element (such as an actuator, a heat transfer layer, or any combination thereof) to at least one retainer. In some embodiments, the method may optionally further include at least partially surrounding the pad and at least one fabric by attaching a decorative cover to at least one retainer. At least one retainer, which may be directly or indirectly attached to at least one fabric, pad, or decorative element, may optionally be one or more of at least one clamping ring, clamp ring, Christmas tree fastener, hook and loop fastener, etc., or any combination thereof. At least one fabric of the decorative assembly manufactured by the foregoing method may be any nonwoven material, fabric, textile, or any combination thereof. In some embodiments, the nonwoven material of at least one fabric further includes jute.

[0469] A component (e.g., seat assembly 520) is described, which may be a vehicle seat, office chair, personal chair, and / or the like. The component (e.g., 520) includes at least one fabric, which may be a non-woven material, a biodegradable plant fiber, jute, and / or an extruded thermoplastic resin material. At least one fabric is sized to displace on the surface of a padding (e.g., 530 and / or 532), which may be a stranded mesh material, a ring of extruded expanded thermoplastic resin, an extruded thermoplastic resin web of extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, or a plurality of fused joints wherein two loops are attached to each other. The padding independently comprises 60% to 95% air by volume, and the padding density is about 0.01 g / cm³. 3 Up to 0.200 g / cm 3At least one retainer (e.g., 542) may be a clamping ring (not directly attached to the pad), a clamping ring, an angled ribbed fastener, a hook-and-loop fastener, a stitch, an adhesive, a weld, a riveting, a connector strip, a retaining clip, a clamp, a barbed fastener, a laminate, and / or a compression molded part. At least one retainer is attached along the periphery of the fabric to at least one fabric to receive a decorative element (e.g., 538 and / or 540). The decorative element may be a decorative cover, a nonwoven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl materials and / or other materials, an actuator such as an airbag assembly (e.g., 538 and / or 540), a heat transfer layer such as a heating pad (e.g., 538 and / or 540), or any combination thereof.

[0470] In some embodiments, the component includes a liner (e.g., 530 and / or 532).

[0471] In some embodiments, the liner (e.g., 530 and / or 532) further includes a stranded mesh material, which may be an extruded thermoplastic resin mesh, strands, three-dimensional loops, or a plurality of fused joints where two loops are attached to each other, the stranded mesh material independently comprising 60% to 95% air by volume, and the density of the stranded mesh material being about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 In this process, at least a subset of the rings in a 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.

[0472] In some embodiments, the component includes a decorative cover, 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 materials, the decorative cover being sized to at least partially enclose a liner (e.g., 530 and / or 532) and at least one fabric, wherein the decorative cover is coupled to at least one retainer.

[0473] In some embodiments, at least one retainer (e.g., 542) includes at least one clamping ring (e.g., 542).

[0474] In some embodiments, at least one retainer (e.g., 542) is not directly coupled to the liner (e.g., 530 and / or 532).

[0475] In some embodiments, at least one fabric further includes a non-woven material.

[0476] In some embodiments, the nonwoven material also includes jute.

[0477] A seating assembly is described, which may be a vehicle seat, office chair, personal chair, and / or the like. The seating assembly includes a seat base, a seat back, and a seat upholstery assembly located in the seat base or seat back. The seat upholstery assembly may be a cover, nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other materials.

[0478] A product is described, which may be a seat bottom pad, a seat back pad, a headrest, a headrest, a cushion, an area and / or a portion thereof. This product is formed by a method comprising: attaching at least one retainer (e.g., 542) to the periphery of at least one fabric, the at least one retainer being a clamping ring (not directly attached to the pad), a clamping ring, an angled ribbed fastener, a hook-and-loop fastener, a stitch, an adhesive, a weld, a riveting, a connector strip, a retaining clip, a clamp, a barbed fastener, a laminate, and / or a compression molding, the at least one fabric being a nonwoven 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 stranded mesh material, a ring of extruded expanded thermoplastic resin, an extruded thermoplastic resin mesh of extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, a plurality of fused joints wherein two loops 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 / cm³. 3 Up to 0.200 g / cm 3 ; and attaching decorative components (which may be nonwoven materials, biodegradable plant fibers, jute, extruded thermoplastic resin materials, one or more sheets of fabric, leather, artificial leather, vinyl materials and / or other materials, which may be actuators of airbag assemblies, heat transfer layers that may be heating pads, or any combination thereof) to at least one retainer (e.g., 542), the attachment utilizing or not utilizing retainers, clamping rings (which are not directly attached to the pads), clamping rings, angled ribbed fasteners, hook and loop fasteners, stitching, adhesives, welds, riveting, connector strips, retaining clips, clamps, barbed fasteners, laminates and / or compression molded parts).

[0479] In some embodiments, the method further includes compressing and molding at least one fabric into the outline of the pad (e.g., 530 and / or 532) before stacking at least one fabric on the pad (e.g., 530 and / or 532).

[0480] In some embodiments, the method further includes attaching a decorative cover (which may be a nonwoven material, biodegradable plant fiber, jute, 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 the pad (e.g., 530 and / or 532) and at least one fabric) to the at least one retainer (e.g., 542), the attachment utilizing or not utilizing a retainer, a clamping ring (which is not directly attached to the pad), a clamping ring, an angled ribbed fastener, a hook-and-loop fastener, a stitch, an adhesive, a weld, a riveting, a connector strip, a retaining clip, a clamp, a barbed fastener, a laminate and / or a compression molded part.

[0481] In some embodiments, stacking at least one fabric on a pad (e.g., 530 and / or 532) also includes stacking at least one fabric on a twisted mesh pad.

[0482] In some embodiments, the method further includes not directly attaching at least one retainer (e.g., 542) to the pad (e.g., 530 and / or 532).

[0483] In some embodiments, the method further includes clamping at least one clamping ring to the fabric as at least one retainer (e.g., 542).

[0484] A seating assembly is described, which may be a vehicle seat, office chair, personal chair, and / or the like. The seating assembly includes a seat base, a seat back, and a product formed according to any of the foregoing or subsequent technologies located in the seat base or seat back.

[0485] Figure 27B Method 2700 according to some embodiments is illustrated. Method 2700 is used to attach a retainer (e.g., 542) (such as a clamping ring (which is not directly attached to the pad), a clamping ring, an angled ribbed fastener, a hook-and-loop fastener, a stitch, an adhesive, a weld, a riveting, a connector strip, a retaining clip, a clamp, a barbed fastener, a laminate, and / or a compression molded part) to a fabric, which may be a nonwoven 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 a different order, sequentially, or simultaneously.

[0486] Method 2700 includes coupling (2702) at least one retainer (e.g., 542) (the coupling may or may not utilize a retainer, a clamping ring (which is not directly coupled to a pad), a clamping ring, an angled ribbed fastener, a hook-and-loop fastener, a sewn-on piece, an adhesive, a welded piece, a riveted piece, a connector strip, a retaining clip, a clamp, a barbed fastener, a laminate, and / or a compression molded piece) to the periphery of at least one fabric, which may be a nonwoven material, a biodegradable plant fiber, jute, and / or an extruded thermoplastic resin material. Method 2700 includes stacking (2704) at least one fabric on a pad (e.g., 530 and / or 532), the pad being a stranded mesh material, a ring of extruded expanded thermoplastic resin, an extruded thermoplastic resin web of extruded expanded thermoplastic resin or polymer, strands, three-dimensional loops, a plurality of fused joints wherein two loops are attached to each other, the pad independently comprising 60% to 95% air by volume, and the pad having a density of about 0.01 g / cm³. 3 Up to 0.200 g / cm 3 Method 2700 includes attaching (2706) a decorative component (which may be a nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material and / or other material, an actuator that may be an airbag assembly, a heat transfer layer that may be a heating pad, or any combination thereof) to at least one retainer (e.g., 542).

[0487] In some embodiments, method 2700 includes at least partially surrounding the padding (e.g., 530 and / or 532) and at least one fabric by attaching a decorative cover (which may be a nonwoven material, biodegradable plant fiber, jute, 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).

[0488] In some embodiments, at least one fabric further includes a non-woven material.

[0489] A decorative component is described, which may be a nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, one or more sheets of fabric, leather, artificial leather, vinyl material, and / or other materials. The decorative component is manufactured by any of the methods described above or below.

[0490] 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 conjunction with one or more methods 400, 1600, 1650, 1680, 3800.

[0491] refer to Figure 28The illustration shows a seat assembly 620, such as a vehicle seat assembly 620. In other examples, the seat assembly 620 may be shaped and sized as a front driver's seat or front passenger seat, a second-row seat, a third-row seat, or other rear seat, and may include bench seats, bucket seats, or other seat styles as shown. Furthermore, the seat assembly 620 may be a non-retractable seat or a retractable seat; a retractable seat may be foldable and can be stored in a cavity in the vehicle floor. Additionally, the seat assembly 620 may be configured for use with other non-vehicle applications.

[0492] 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 base 624 and a seat back 626. The seat base 624 may be sized to accommodate a seated occupant to support the occupant's pelvis and thighs. The seat back 626 may be sized to extend upright from the seat base 624 to support the occupant's back. Seat assembly 620 may additionally have a headrest 627, wherein the headrest 627 is shown as being used only for adjacent seat assemblies.

[0493] Seat assembly 620 has a pad 640 defining a seat bottom pad region 628 for seat bottom 624 and a seat back pad region 630 for seat back 626. Frame 622 may include wire suspension pads or other structures to support pad 640. Pad 640 is described in more detail below with reference to various examples and embodiments.

[0494] Frame 622 provides rigid structural support for seat components (e.g., cushion 640, seat bottom 624, and seat back 626) and may be configured as multiple frame members that are movable relative to each other to provide adjustment of the seat assembly. The frame may be formed from stamped steel alloy, fiber-reinforced polymer, or any suitable structural material. Frame 622 may also include a substrate (e.g., a panel) to support cushion 640.

[0495] One or more decorative covers 632 are used to cover the padding 640 and provide a seat surface 654 for the seat assembly 620. A vehicle seat assembly 620 without a decorative cover is shown, and adjacent seat assemblies show decorative covers 632. In one example, the decorative cover 632 covers both padding areas 628 and 630. In other examples, multiple decorative covers are provided to cover the seat bottom padding area and the seat back padding area. The decorative cover 632 may be formed from one or more sheets of fabric, leather, artificial leather, vinyl, or other materials.

[0496] 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 solely of member 642, such that the non-foam component 642 provides all cushioning for the seat component between the frame 622 and the cover 632. In other examples, the seat cushion 640 may be formed of member 642 and one or more foam components (such as those formed from molded polyurethane foam) and / or one or more non-foam components (such as auxiliary members 648 described below). The seat cushion 640 may have both non-foam and foam components positioned to provide different areas of the cushion 640 for the seat component (e.g., a central area and side cushion areas). Alternatively or additionally, the seat cushion 640 may have a thin layer of foam or other material positioned between the cushion 640 and the cover 632 to provide additional cushioning for one or more areas of the seat component. In addition, seat assembly 620 may have a heating pad or heating mat positioned between cushion 640 and trim cover 632. By removing some or all of the conventional foam from seat cushion 640, seat assembly 620 can provide improved support and comfort, as well as reduced weight.

[0497] In a non-limiting example, the non-foamed component or member 642 of the seat cushion 640 is formed of a stranded mesh material (also known as an entangled three-dimensional filament structure). The stranded mesh material is made of a polymer web having multiple integrated polymer strands. The stranded mesh material can be made of, for example, linear low-density polyethylene (LLDPE), but other polymers and materials are also envisioned to effectively provide the desired properties and functions. The stranded 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 [example of porous mesh structure]. Figure 29 It is shown in a close-up view.

[0498] refer to Figure 28 , Figure 33 and Figure 37 The diagram illustrates a component 642 according to various embodiments. Component 642 can be used as a liner for a seat assembly (such as vehicle seat assembly 620) or for other non-vehicle or non-seat applications. Component 642 of the liner 640 can be formed from a stranded mesh material as a single integral part, for example, from a single extrusion as described below, and can be formed solely from the stranded mesh material. Furthermore, the stranded mesh material may comprise a polymer web having a plurality of integrated polymer strands as described above.

[0499] Component 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 defined by the outer periphery of the component. In various examples, the first end region 650 is shaped to define or provide a seat back padding region 630, and the second end region 652 is shaped to define or provide a seat bottom padding region 628.

[0500] Member 642 further defines a first surface 654 for supporting an occupant on a cushion and a second surface 656 opposite to and spaced apart from the first surface. The first surface 654 extends across a first end region 650 and a 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. A side surface 658 may extend around the periphery of member 642 and between the first surface 654 and the second surface 656.

[0501] Component 642 in Figure 32 and Figure 36 The text is shown as being in the first position, and in such a position... Figure 28 , Figure 33 and Figure 37 The image shown is in the second usage position. Figure 28 , Figure 33 and Figure 37 In this embodiment, member 642 has a first end region 650 positioned at a non-zero angle θ relative to the second end region 652. In a non-limiting example and as shown... Figure 33 and Figure 37 As shown, the non-zero angle θ can be in the range of 90 degrees to 120 degrees, and further, it can be in the range of 90 degrees to 150 degrees. Other non-zero angle ranges are also conceivable in other examples. In the first position, the member 642 is provided in the shape of extrusion, and furthermore, the first end region 650 and the second end region 652 can be oriented relative to each other at an angle of zero degrees or substantially zero degrees. As used herein, substantially means within a range of five, ten, or fifteen degrees of said orientation. The member 642 can be bent, folded, flexed, or otherwise oriented from the first position to the second position, as further described below.

[0502] According to the example, component 642 is from... Figure 32 The first position shown is shaped, bent, folded, or folded to, as Figure 33 The second position shown. As shown, the transition region 660 can be located between the first end region and the second end region.

[0503] According to another example, member 642 may be formed or provided with one or more channels 662 that provide relief for shaping, bending, folding, or folding 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 member 642. Channels 662 may extend across the entire member 642 or only a portion thereof. In the example shown, channel 662 intersects with a first surface 654 of member 642 and is configured as an open channel that does not intersect with a second surface 656. In other examples, channels may additionally or alternatively intersect with the second surface 656 and / or side surfaces 658. Channels 662 may be positioned between a first end region 650 and a second end region 652 of member 642, for example, in a transition region 660, to provide relief for bending or shaping member 642 from a first position to a second position.

[0504] In one example, each channel 662 has a first face 664 and a second face 672, and when the member is in a first position, the channel 662 can be shaped as a V-shape, U-shape, or other cross-sectional shape. A V-shaped channel 662 is shown according to a non-limiting example. When the member 642 is in such a position... Figure 37 In the second position shown, the first surface 664 and the second surface 672 engage with each other, contact each other, or otherwise move toward each other.

[0505] The first surface 664 and the second surface 672 can be connected to each other to hold the member 642 in such a way as Figure 37 The second position is shown. In one example, one or more channel fasteners 668 are provided to connect the first face 664 to the second face 672 and hold the member 642 in the second position. The channel fasteners 668 may be provided by clamps, hook fasteners, barbed fasteners, clips, etc. In another example, the first face 664 and the second face 672 may be additionally or alternatively joined together, for example, by adhesive, or by a lamination or welding process in which strands on one face are melted to strands on another face.

[0506] In other examples, additional channels may be additionally or alternatively formed or provided in member 642 and extend in various directions, and may also be positioned to intersect with the second surface 656, side surface 658 or multiple surfaces.

[0507] In various examples, the liner 640 also includes one or more auxiliary members 648 supported by member 642, such as Figure 28 and Figure 34As shown. These auxiliary components 648 may be provided as individual extrusions of stranded mesh material, other non-foamed materials, foam such as molded polyurethane foam, or combinations thereof. The auxiliary component 648 may extend outward from the first surface 654 and / or the second surface 656 of the component 642, and may extend outward from the first end region 650 and / or the second end region 652. In one example, the auxiliary component 648 may form an element of the padding 640, such as a side cushion, lumbar support, or pillow.

[0508] Auxiliary member 648 can be attached to member 642 to form gasket 640. In one example, one or more auxiliary fasteners 670 are provided to attach auxiliary member 648 to member 642. Auxiliary fasteners 670 can be provided as clamps, hook fasteners, barbed fasteners, clips, etc. In another example, auxiliary member 648 can be additionally or alternatively attached to member 642, for example, via adhesive, or via a lamination or welding process by melting strands from one side to strands from another side.

[0509] Although only relative to Figure 28 and Figure 34 Auxiliary member 648 is shown, but it is also conceivable that the auxiliary member can be attached to... Figure 37 Component 642 or otherwise made by Figure 37 Component 642 supports.

[0510] Figure 30 A manufacturing process 700 for forming stranded mesh material components (such as component 642 for pad 640) according to an embodiment is shown.

[0511] Hopper 710 contains the material feedstock to be extruded, such as solid particles or spheres as material. The material can be supplied by plastic (e.g., linear low-density polyethylene (LLDPE)). Material 14 is supplied from hopper 710 to extruder 720.

[0512] Extruder 720 melts material and conveys it to die 730. In a non-limiting example, extruder 720 includes a barrel receiving a rotatable screw and a heating element. The rotation of the screw forces the material to move through the barrel, and the friction generated during screw rotation helps heat the material. The material exits extruder 720 under pressure and in a molten state.

[0513] The template 730 extrudes material into filaments 740. The template 730 can be configured according to the orientation of the extrudate relative to the final component 642 produced therefrom, as described below. More specifically, the template 730 has a plurality of small circular through-holes or orifices through which molten material passes. Individual filaments 740 are extruded from each template orifice. Under system pressure and gravity, the filaments 740 fall downwards from the template into a funnel 750, as described below. The funnel 750 can have the same or different cross-sectional shape as the orifices in the template.

[0514] The funnel 750 facilitates the consolidation or grouping of the filaments 740 into a more compact arrangement in which the filaments 740 are bent or looped, and each filament 740 contacts and joins with at least one other filament 740. The funnel 750 has a funnel inlet and a funnel outlet smaller than the funnel inlet. The funnel 750 is narrower at the funnel outlet than at the funnel inlet. Individual, separate filaments 740 enter the funnel inlet, and as these filaments gather and slide down the funnel 750 toward the funnel outlet, the filaments 740 bend / loop and move into contact with each other, and the consolidated filament structure 760 exits the funnel outlet and immediately enters the tank. In various examples, the filament structure can slide down an angled surface of the funnel 750, thereby creating a material skin for the structure 760, which is formed by two to three rows of filaments adjacent to the periphery of the structure 760.

[0515] Liquid tank 770 contains water 772 or other fluids and receives the solidified filament structure 760 from funnel 750. The liquid 772 in the bath 770 helps to temporarily support the solidified filament structure 760, preventing it from collapsing or condensing into a less open or less porous arrangement, and maintaining the desired porosity and density. Therefore, liquid 772 provides some resistance that causes additional bending and looping of the filaments 740 to further build the solidified filament structure 760. Secondly, liquid 772 cools the filaments 740 from the outside to solidify them and prevent them from bonding in other locations.

[0516] The container 770 includes various rollers and conveyors, such as a traction conveyor 780, that facilitate the movement of the bound filament structure 760 through and out of the liquid 772. The speeds of the rollers and conveyors can be controlled so that the bound filament structure 760 moves away from the funnel 750 at a speed related to the speed at which the bound filament structure 760 leaves the funnel 750.

[0517] Other rollers (such as roller 782) help keep the bound filament structure 760 submerged in the liquid 772 and guide the bound filament structure 760 through the liquid 772 toward the conveyor belt 790 and the shaking table 792 located outside the box 770. While the bound filament structure 760 is on the conveyor belt 790, the shaking table 792 shakes the bound filament structure 760 to remove the liquid 772. Pressurized air may additionally or alternatively be blown toward the bound filament structure 760, and / or the bound filament structure 760 may be squeezed to remove the liquid 772.

[0518] The bonded filament structure 760 can then be cut to the desired size and shape. In one example, and for such... Figure 30 The mold 730 or funnel 750 shown, through a cut across the solidified filament structure 760, forms the first surface 654 or the second surface 656 of the member 642. In another example, and for such Figure 35 The mold 730 or funnel 750 shown is cut through the solidified filament structure to form the side surface 658 of the component 642.

[0519] Alternatively, component 642 may be further machined or cut to form channels, pathways or shapes within component 642.

[0520] Figure 31 It shows the use of with Figure 30 A top view of the tools 800 (such as mold 730 and / or funnel 750) used in the manufacturing process 700 and according to the embodiment. Figure 32 It shows the first configuration or position and is by Figure 31 A side view of the stranded mesh material component 642 provided by tool 800. Note that in Figure 28 The perspective view of the resulting component 642, which is based on a non-limiting example and is in a second position, can be seen in the image.

[0521] In one example Figure 31 A top view of a tool 800 serving as a mold 730 is shown, in which a filament flows downward into the mold 730. Orifices 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 padding region and a seat base padding region. The funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the pattern formed by the mold orifices.

[0522] For the resulting consolidated filament structure 760, the structure is cut such that the cut forms the first surface 654 or the second surface 656 as described above, and the member 642 retains the outer peripheral shape as indicated by the mold and / or funnel pattern / periphery 802. Furthermore, when, for example, passing through a reference... Figure 31When the page is cut and the bonded filament structure 760 is cut, the side surface 658 of the resulting component 642 is formed by the extruded bonded filament structure 760. Therefore, the thickness of the component 642 or the length of the side surface 658 is determined by the cutting position of the bonded filament structure 760.

[0523] Figure 35 It shows the use of with Figure 30 A top view of a tool 820 (such as a mold 730 and / or a funnel 750) used in the manufacturing process 700 and according to another embodiment. Figure 36 It shows the first configuration or position and is by Figure 31 A side view of the stranded mesh material component 642 provided by tool 820. Note that in Figure 28 The perspective view of the resulting component 642, which is based on a non-limiting example and is in a second position, can be seen in the image.

[0524] In one example Figure 35 A top view of a tool 820 serving as a mold 730 is shown, in which a filament flows downward into the mold 730. Orifices are arranged in a pattern as shown within a bounded perimeter 822 to form a first end region 650 and a second end region 652 of the component (e.g., a seat back padding region and a seat base padding region), and a channel through region 824. The funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the pattern formed by the mold orifices and the channel 662. The funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the perimeter 822 formed by the mold orifices. In other examples, only the funnel 750 forms region 824 to provide a channel in the filament structure, and the mold 730 does not have this structure.

[0525] For the resulting consolidated filament structure 760, the structure is cut such that the cut forms the side surface 658 as described above, and the component 642 maintains the cross-sectional shape as shown in the mold pattern and / or funnel shape 822. Furthermore, when the consolidated filament structure 760 passes, for example through a reference... Figure 35 During the page cutting, the first surface 654 and the second surface 656 of the resulting component 642 are formed by the extruded and bonded filament structure, for example, by the edges 826, 828 of the die 730. Therefore, the width of the component 642 or the distance between the opposing side surfaces 658 on the left and right sides of the component 642 is determined by the cutting position of the bonded filament structure 760.

[0526] In another example, the die 730 and funnel 750 may be shaped as a longitudinal (e.g., from top to bottom) extrusion and may include a region 824 to form a channel extending longitudinally along the member rather than laterally 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 filament structure 760. Therefore, the length of member 642, or the distance between the top of member 642 adjacent to the headrest and the relative bottom of member 642, is determined by the cutting position of the consolidated filament structure and the formation position of the side surfaces of the top and bottom of member 642.

[0527] A method is provided, which can be used to form component 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 a different order, sequentially, or simultaneously.

[0528] Component 642 uses a stranded mesh material, for example via the above-mentioned Figure 30 The process described above forms a stranded mesh material. The material can 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 component, discharging the extruded material from the die through a funnel 750, and moving the extruded material via one or more rollers 780, 782 after discharge.

[0529] Furthermore, one or more channels 662 may be formed during at least one of the processes of extruding material, discharging the extruded material, and moving the extruded material. Alternatively, channels 662 may be formed in member 642 after the consolidated filament structure 760 has been cut to form the member.

[0530] The extruded material or consolidated filament structure 760 is cut to form at least one outer surface of the component. The outer surface may extend across a first end region 650 and a second end region 652, and may be a first surface 654, a second surface 656, or a side surface 658. When the component 642 is cut from the consolidated filament structure 760, the component 642 is in the position as... Figure 32 and Figure 36 The first position is shown. Component 642 may also be machined or otherwise processed to form other features, such as channels or pathways for connecting trim components or for positioning or receiving various parts or systems of the seat assembly.

[0531] The first end region 650 of the stranded mesh material member 642 is oriented at a non-zero angle relative to the second end region 652 of the member, so as to move the member from the first position as Figure 33 and Figure 37The second position is shown. In one example, the twisted mesh material member 642 is bent or flexed from the first position to the second position to orient the member. Channel 662 (if provided) can provide a pressure relief or position for the bend or curve.

[0532] The first end region 650 is held at a non-zero angle relative to the second end region 652, and the member 642 is in the second position. In various examples, one or more channel fasteners 668 are inserted into opposite sides or faces 664, 672 of the channel, the opposite sides 664, 672 of the channel being joined together, or a combination of both, to hold the first end region 650 in the second position relative to the second end region 652.

[0533] Form one or more auxiliary components 648. The auxiliary components 648 may be formed from the components described above. Figure 30 The process description and Figure 29 The stranded mesh material shown is formed similarly to the stranded mesh material and is formed separately from member 642. Alternatively, auxiliary member 648 may be formed as other non-foam or foam members. Auxiliary member 648 is attached to member 642. Auxiliary member 648 may be attached to member 642 when member 642 is in a first position and / or a second position. Auxiliary member 648 may also be attached to a first surface 654, a second surface 656, and / or a side surface 658 of member 642. In various examples, one or more auxiliary fasteners 670 are inserted into auxiliary member 648 and member 642 to bind auxiliary member 648 to member 642, or a combination of both to retain auxiliary member 648 to member 642.

[0534] Component 642 is attached to the frame 622 of the seat assembly to provide a padding 640 for the frame of the seat assembly. A decorative cover 632 may be positioned above component 642 and padding 640. Decorative cover 632 may be connected to padding 640 and / or frame 622.

[0535] Various embodiments provide a single extrusion of component 642 to produce an overall area for cushion 640, including seat back 626 and seat bottom 624. By further including channel 662 and / or auxiliary component 648, the desired shape of cushion 640 is provided while maintaining ease of single extrusion.

[0536] The terms "seat assembly," "seat," or "chair" may be used herein to generally refer to an component incorporating the teachings of one or more embodiments disclosed herein, which may include any combination of the features of the disclosed embodiments or embodiments. Similarly, the terms "seat assembly," "seat," or "chair" may refer to the same or similar components. The terms "seat bottom," "backrest," "base," "headrest," "headrest," or "cushion" may be used herein to generally refer to any part, area, or portion of a seat assembly, vehicle seat, or chair. The terms "layer," "sheet," "substrate," "part," "section," "area," or "segment" may refer to any planar, non-planar, shaped, or contoured portion or area of ​​a seat bottom, backrest, base, headrest, headrest, or cushion formed of any of the disclosed materials or combinations of materials to provide comfort and / or structure for the seat bottom, backrest, base, headrest, headrest, or cushion. The terms "joining," "connecting," "welding," "stitching," "fastening," "holding," "adheding," "attaching," "coupling," or "riveting" can refer to any manufacturing method or process used to connect components, whether or not it utilizes fasteners, retainers, adhesives, weldments, clamps, connector strips, retaining clips, hook-and-loop fasteners, jigs, angled ribbed fasteners, barbed fasteners, laminates, compression molded parts, or additional decorative parts. Following distribution through one or more orifices of a die, plate, template, tool, tool plate, extrusion die, or baffle plate, or other variations thereof, filaments, strands, bends, or rings can be used herein to refer to generally linear polymer units (although they may be ringed, fused, or joined together to form a mesh structure), and they are also used to refer to equivalent components. Similarly, the terms: consolidated filament structure, filament structure, entangled filament structure, yielded strand, body, net, final component, non-foamed component, non-woven net, non-foamed material, support, component, core, member, extruded material, cushioning, padding or padding 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 may also use various terms to refer to holes, such as orifices, pores, nozzles, openings, etc. In yet another example, tank, water tank, cooling chamber, liquid tank, and vessel can refer to the same or similar components. When describing different preferred embodiments, different terms may be used to refer to the same or similar components to avoid confusion. These terms may be interchangeable because various components from the features of various embodiments can be combined in ways not explicitly described herein. This does not diminish the fact that certain terms can provide inherent details not included in other interchangeable terms unless otherwise explicitly stated (e.g., water tank and fluid tank refer to similar interchangeable components, but in at least one preferred embodiment, the tank is filled with water or arranged to be filled with water, rather than any liquid, when using the tank).

[0537] A padding (e.g., 640) is described, which may be a seat bottom padding, a seat back padding, a headrest, a headrest, a cushion, a region, or a portion. The padding (e.g., 640) includes a component (e.g., 642), which may be foam, non-foam, and / or a combination thereof. The component (e.g., 642) includes a stranded mesh material, which may be a polymer web having multiple integrated polymer strands, an entangled three-dimensional filament structure, linear low-density polyethylene, or extruded filaments that are randomly entangled, bent, looped, or otherwise positioned and oriented, and / or directly bonded to each other to provide a porous mesh structure. The component (e.g., 642) defines a first end region (e.g., 650) and a second end region (e.g., 652), the first end region being shaped to define a seat back padding, and the second end region being shaped to define a seat base padding. The first end region (e.g., 650) and the second end region (e.g., 652) are defined by the outer periphery of the component (e.g., 642). The first end region (e.g., 650) is positioned (bent, folded, bent and / or oriented) relative to the second end region (e.g., 652) at a non-zero angle (such as 90-120 degrees, or 90-150 degrees).

[0538] In some embodiments, the component (e.g., 642) is formed solely of a stranded mesh material.

[0539] In some embodiments, the stranded mesh material comprises a polymer mesh having a plurality of integrated polymer strands.

[0540] In some embodiments, a first end region (e.g., 650) is shaped to define a seat backrest pad; and a second end region (e.g., 652) is shaped to define a seat base pad.

[0541] In some embodiments, the component (e.g., 642) further includes a first surface for supporting an occupant on a pad (e.g., 640) and a second surface opposite to 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.

[0542] In some embodiments, the component (e.g., 642) defines one or more channels, which may be V-shaped, U-shaped and / or provide pressure relief for shaping, bending, folding or folding, each channel intersecting one of the first and second surfaces, each channel may extend laterally and / or intersect with the side surfaces.

[0543] In some embodiments, the channel extends laterally across the member (e.g., 642) and is positioned between a first end region (e.g., 650) and a second end region (e.g., 652).

[0544] In some embodiments, the channel includes a first surface and a second surface, wherein the first surface and the second surface cooperate with each other.

[0545] In some embodiments, the gasket (e.g., 640) further includes one or more channel fasteners (e.g., 668) that connect the first face to the second face to hold the first end region (e.g., 650) at a non-zero angle relative to the second end region (e.g., 652).

[0546] In some embodiments, one or more auxiliary components (e.g., 648) (such as a pillow or lumbar support) are supported by a component (e.g., 642).

[0547] In some embodiments, the auxiliary component (e.g., 648) comprises a twisted mesh material.

[0548] In some embodiments, an auxiliary member (e.g., 648) extends outward from at least one of a first end region (e.g., 650) and a second end region (e.g., 652) of a member (e.g., 642).

[0549] In some embodiments, the liner (e.g., 640) also includes one or more auxiliary member (e.g., 648) fasteners, which may be clamps, hook fasteners, barbed fasteners, clips, adhesives, laminates and / or welds for connecting the auxiliary member (e.g., 648) to the member (e.g., 642).

[0550] In some embodiments, an auxiliary member (e.g., 648) is shaped and positioned on a member (e.g., 642) to form a side cushion or lumbar support.

[0551] A seating assembly is described, which may be a vehicle seat, office chair, and / or personal chair. The seating assembly includes: a frame, which may be a stamped steel alloy, fiber-reinforced polymer, and / or any suitable structural material; wire suspension pads; a substrate and / or sheet material; and a pad (e.g., 640) according to any of the foregoing or subsequent techniques. The pad (e.g., 640) is supported by the frame.

[0552] A tool is described. The tool includes: a die (e.g., 730) (or funnel) defining a series of orifices arranged to extrude material for a stranded mesh material member for a pad (e.g., 640) according to any of the foregoing or subsequent techniques. The series of orifices are arranged to define the outer periphery of a member (e.g., 642) comprising a seat back area and a seat base area.

[0553] In some embodiments, a series of orifices are also arranged such that the outer periphery defines one or more channels for the component (e.g., 642).

[0554] In some embodiments, a series of openings are arranged such that one or more channels are positioned between the seat back area and the seat base area.

[0555] Figure 38 Method 3800 according to some embodiments is illustrated. Method 3800 is used to position (such as bending, folding, flexing, and / or orienting) a stranded mesh material component, which may be a polymer web having multiple integrated polymer strands, an entangled three-dimensional filament structure, linear low-density polyethylene, extruded filaments that are 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, method 3800 may have more or fewer steps than described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0556] Method 3800 includes: positioning (3802) at a non-zero angle (e.g., 90-120 degrees and / or 90-150 degrees) relative to a second end region (e.g., 652) of a stranded mesh material member (e.g., 642) (e.g., bending, folding, and / or orienting) a first end region (e.g., 650) of the member (642), the first end region being shaped to define a seat back cushion, the stranded mesh material member being a polymer mesh having multiple integrated polymer strands, an entangled three-dimensional filament structure, linear low-density polyethylene, extruded filaments randomly entangled, bent, looped, or otherwise positioned and oriented and / or directly bonded to each other to provide a porous mesh structure; and retaining (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 the use of hooks, hook fasteners, barbed fasteners, clips, adhesives, laminates, and / or welds.

[0557] In some embodiments, method 3800 includes forming a stranded mesh material component by extruding material through a die (e.g., 642).

[0558] In some embodiments, a stranded mesh material member (e.g., 642) is extruded to form a first end region (e.g., 650) and a second end region (e.g., 652).

[0559] In some embodiments, forming the stranded mesh material component (e.g., 642) further includes discharging the extruded material from the die through a funnel.

[0560] In some embodiments, method 3800 includes moving the extruded material via one or more rollers after discharge.

[0561] In some embodiments, method 3800 includes forming one or more channels (which may be achieved by means of extrusion, die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automation) during at least one of extruding material, discharging the extruded material and moving the extruded material.

[0562] In some embodiments, method 3800 includes cutting one or more channels in a component (e.g., 642), which may be achieved by means of die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automation.

[0563] In some embodiments, method 3800 includes inserting one or more fasteners (such as clamp rings, hook ring fasteners, barbed fasteners, clips, adhesives, laminates and / or welds) into opposite sides of a channel and / or combining opposite sides of a channel to retain a first end region (e.g., 650) relative to a second end region (e.g., 652).

[0564] In some embodiments, method 3800 includes cutting extruded material (which may be achieved by means of die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automation) to form an outer surface of a component (e.g., 642) that extends across a first end region (e.g., 650) and a second end region (e.g., 652).

[0565] In some embodiments, method 3800 includes bending a stranded mesh material member (e.g., 642) from a first position to a second position to orient the member (e.g., 642).

[0566] In some embodiments, method 3800 includes attaching one or more auxiliary components (e.g., 648) (which may use clamp rings, hook ring fasteners, barbed fasteners, clips, adhesives, laminates and / or welds) to a component (e.g., 642).

[0567] In some embodiments, method 3800 includes, for example, forming an auxiliary member by extruding a stranded mesh material (e.g., 648).

[0568] In some embodiments, attaching an auxiliary member (e.g., 648) to a member (e.g., 642) further includes inserting one or more fasteners (which may be clamp rings, hook ring fasteners, barbed fasteners, clips, adhesives, laminates and / or welded parts) into the auxiliary member (e.g., 648) and the member (e.g., 642), and / or bonding the auxiliary member (e.g., 648) to the member (e.g., 642).

[0569] In some embodiments, method 3800 further includes attaching a component (e.g., 642) to a frame of the seat assembly (e.g., stamped steel alloy, fiber-reinforced polymer or any suitable structural material, wire suspension pad, substrate and / or sheet) to provide padding (e.g., 640) for the frame.

[0570] The above techniques may optionally be combined with one or more elements of the above methods. For example, these parts may be used in conjunction with another method 400, 1600, 1650, 1680, 2700.

[0571] Clause 1. A seat support, in conjunction with or without any of the following 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 on top of each other, and each of the plurality of stacked layers has a varying density.

[0572] Clause 2. A seat support according to any of the foregoing or subsequent clauses, wherein the density of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0573] Clause 3. A seat support according to any of the foregoing or subsequent clauses, wherein the firmness of the plurality of stacked layers varies in a sequentially increasing manner from the occupant support surface to the base layer.

[0574] Clause 4. Seat support according to any of the foregoing or subsequent clauses, wherein multiple stacked layers are connected together.

[0575] Clause 5. Seat support according to any of the foregoing or subsequent clauses, wherein each sequential pair of a plurality of stacked layers is combined together.

[0576] Clause 6. Seat support according to any of the foregoing or subsequent clauses, wherein each sequential pair of a plurality of stacked layers is welded, stitched, fastened or adhered together.

[0577] Clause 7. Seat support according to any of the foregoing or subsequent clauses, wherein the multiple stacked layers further include rubber, thick blanket, needle-punched cotton fabric, polyethylene terephthalate or polypropylene.

[0578] Clause 8. A seat support according to any of the foregoing or subsequent clauses, wherein the plurality of stacked layers further includes a base layer adapted for mounting to a seat frame, wherein the base layer is formed of a denser material than the other layers in the plurality of stacked layers.

[0579] Clause 9. Seat support according to any of the foregoing or subsequent clauses, wherein the base layer is formed of an elastomeric material.

[0580] Clause 10. Seat support according to any of the foregoing or subsequent clauses, wherein the base layer is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

[0581] Clause 11. Seat support according to any of the foregoing or subsequent clauses, wherein the base layer has a thickness of two millimeters or less.

[0582] Clause 12. A seat assembly comprising: a base plate adapted for mounting to a seat frame; and a seat support stacked on the base plate according to any of the foregoing or subsequent clauses.

[0583] Clause 13. A seat assembly according to any of the foregoing or subsequent clauses, wherein the substrate is formed of an elastomeric material.

[0584] Clause 14. A seat assembly according to any of the foregoing or subsequent clauses, wherein the substrate is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or expanded polyvinyl chloride.

[0585] Clause 15. The seat assembly pursuant to any of the foregoing or subsequent clauses also includes a seat frame, wherein the substrate is attached to the seat frame.

[0586] Clause 16. A seat support, in combination with or without any of the foregoing or subsequent clauses, the seat support 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 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.

[0587] Clause 17. A method for manufacturing a seat assembly, in combination or not in combination with any of the foregoing 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 onto 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 onto the first seat support layer.

[0588] Clause 18. The method according to any of the foregoing or subsequent clauses further includes: 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 mounting the third seat support layer onto the second seat support layer.

[0589] Clause 19. The method according to any of the foregoing or subsequent clauses also includes incorporating the second seat support layer into the first seat support layer.

[0590] Clause 20. A seat assembly manufactured by a method pursuant to any of the foregoing or subsequent clauses.

[0591] Clause 21. A seat support, in combination with or without any of the foregoing or subsequent clauses, the seat support comprising a plurality of layers of extruded thermoplastic resin mesh for mounting to a seat frame and supporting an occupant on the seat frame, wherein the plurality of layers are stacked on top of each other.

[0592] Clause 22. A seat support according to any of the foregoing or subsequent clauses, wherein at least one of the plurality of stacked layers has a substantially uniform thickness.

[0593] Clause 23. A seat support according to any of the foregoing or subsequent clauses, wherein each of the plurality of stacked layers has a substantially uniform thickness.

[0594] Clause 24. A seat support according to any of the foregoing or subsequent clauses, wherein the seat support further comprises at least two stacked layers.

[0595] Clause 25. A seat support according to any of the foregoing or subsequent clauses, wherein each of the plurality of stacked layers is pivotally connected to each other.

[0596] Clause 26. A seat support according to any of the foregoing or subsequent clauses, wherein at least one recess is formed into one of a plurality of stacked layers to provide a pivot connection.

[0597] Clause 27. Seat support according to any of the foregoing or subsequent clauses, wherein each of the plurality of stacked layers is integrally formed.

[0598] Clause 28. A seat assembly comprising: a seat frame; and a seat support attached to the seat frame according to any of the foregoing or subsequent clauses.

[0599] Clause 29. A seat support, in combination with or without any of the foregoing or subsequent clauses, the seat support 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 on top of each other; 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 each other.

[0600] Clause 30. A method of manufacturing an article, in combination with or without any of the foregoing or subsequent clauses, the method comprising: forming a plurality of pad segments by extruding a thermoplastic resin web; and stacking the plurality of pad segments into a pad.

[0601] Clause 31. The method according to any of the foregoing or subsequent clauses also includes forming a plurality of gasket segments.

[0602] Clause 32. The method according to any of the foregoing or subsequent clauses also includes forming a plurality of pad segments into a single sheet.

[0603] Clause 33. The method according to any of the foregoing or subsequent clauses also includes folding the padding segments so that the padding segments are stacked on top of each other.

[0604] Clause 34. The method according to any of the foregoing or subsequent clauses further includes forming at least one recess in at least one of the plurality of padding segments to fold the padding segment.

[0605] Clause 35. The method according to any of the foregoing or subsequent clauses also includes cutting multiple liner segments to form multiple liner segments.

[0606] Clause 36. A seat support manufactured by a method according to any of the foregoing or subsequent clauses.

[0607] Clause 37. The method according to any of the foregoing or subsequent clauses also includes mounting the product to the seat frame.

[0608] Clause 38. A seat assembly manufactured by a method pursuant to any of the foregoing or subsequent clauses.

[0609] Clause 39. A method for designing a seat cushion, in combination with or without any of the foregoing or subsequent clauses, the method comprising: obtaining a design for a monolithic seat cushion; and redesigning the monolithic seat cushion design into a design of multiple stacked cushion segments.

[0610] Clause 40. The method according to any of the foregoing or subsequent clauses also includes redesigning the monolithic seat cushion design into a design of multiple stacked cushion segments, each having a common maximum thickness.

[0611] Clause 41. A method of manufacturing a seat cushion, the method comprising: designing a plurality of seat cushion segments according to any of the foregoing or subsequent clauses; and forming the plurality of cushion segments by extruding a thermoplastic resin web.

[0612] Clause 42. The method according to any of the foregoing or subsequent clauses also includes stacking multiple pad segments as pads.

[0613] Clause 43. A vehicle seat cushion component, in combination with or without any of the foregoing or subsequent clauses, the vehicle seat cushion component comprising: a first plastic mesh cushion pillow including a first plurality of three-dimensional loops made of a first thermoplastic polymer; a second plastic mesh cushion pillow including a second plurality of three-dimensional loops made of a second thermoplastic polymer; and a plastic mesh base including a third plurality of three-dimensional loops made of a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first surface, and a second surface, 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 second edge.

[0614] Clause 44. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the vehicle seat cushion component is included in the vehicle seat back or the vehicle seat bottom.

[0615] Clause 45. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first plurality of three-dimensional loops, the second plurality of three-dimensional loops and the third plurality of three-dimensional loops each independently include a plurality of fused joints, in which two loops are attached to each other.

[0616] Clause 46. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first plurality of three-dimensional loops and the second plurality of three-dimensional loops are each independently formed in the form of a vehicle seat cushion.

[0617] Clause 47. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein a first plastic mesh cushion and a second plastic mesh cushion are each disposed above the first surface.

[0618] Clause 48. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein a first plastic mesh cushion is attached to a first edge and a second plastic mesh cushion is attached to a second edge.

[0619] Clause 49. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first plastic mesh cushion and the second plastic mesh cushion are attached to the plastic mesh base by hook and loop strips, adhesives, retaining clips and / or clamping rings.

[0620] Clause 50. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein at least a subset of the loops in the first plurality of three-dimensional loops, at least a subset of the loops in the second plurality of three-dimensional loops, and at least a subset of the loops in the third plurality of three-dimensional loops are not parallel or misaligned with each other.

[0621] Clause 51. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein at least a subset of the rings in the first plurality of three-dimensional loops, at least a subset of the rings in the second plurality of three-dimensional loops, and at least a subset of the rings in the third plurality of three-dimensional loops are randomly oriented.

[0622] Clause 52. For any of the preceding or subsequent clauses, the first skin layer is disposed on the first surface of the plastic mesh base.

[0623] Clause 53. For any of the preceding or subsequent clauses, the first skin layer is disposed on the second surface of the plastic mesh base.

[0624] Clause 54. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first plastic mesh cushion, the second plastic mesh cushion, and the plastic mesh base independently comprise 60% to 95% by volume air.

[0625] Clause 55. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first plastic mesh cushion, the second plastic mesh cushion, and the plastic mesh base independently have a density of approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0626] Clause 56. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first thermoplastic polymer, the second thermoplastic polymer and the third thermoplastic polymer are each independently extruded thermoplastic polymers.

[0627] Clause 57. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, 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.

[0628] Clause 58. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first thermoplastic polymer, the second thermoplastic polymer and the third thermoplastic polymer are each independently linear low-density polyethylene.

[0629] Clause 59. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first plurality of three-dimensional loops, the second plurality of three-dimensional loops and the third plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex.

[0630] Clause 60. A vehicle seat cushion component, in combination with or without any of the foregoing or subsequent clauses, the vehicle seat cushion component comprising: a first plastic mesh cushion pillow including a first plurality of three-dimensional loops made of a first thermoplastic polymer; a second plastic mesh cushion pillow including a second plurality of three-dimensional loops made of a second thermoplastic polymer; and a plastic mesh substrate including a third plurality of three-dimensional loops made of a third thermoplastic polymer, the plastic mesh substrate having a first edge, a second edge, a first surface, and a second surface, wherein the first plastic mesh cushion pillow is attached to the plastic mesh substrate at the first edge, and the second plastic mesh cushion pillow is attached to the plastic mesh substrate at the second edge, wherein the first plurality of three-dimensional loops, the second plurality of three-dimensional loops, and the third plurality of three-dimensional loops each independently include a plurality of fused joints in which two loops are attached to each other.

[0631] Clause 61. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the vehicle seat cushion component is included in the vehicle seat back or the vehicle seat bottom.

[0632] Clause 62. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the plastic mesh base contains 60% to 95% air by volume.

[0633] Clause 63. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, 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.

[0634] Clause 64. A vehicle seat cushion component, in combination or not in combination with any of the foregoing or subsequent clauses, the vehicle seat cushion component comprising: a first cushion assembly including a first core cushion portion surrounded by a first outer cushion cover, the first outer cushion cover being surrounded by a first cushion trim cover; a second cushion assembly including a second core cushion portion surrounded by a second outer cushion cover; and a trim cover portion having a first edge and a second edge, the first cushion assembly being sewn to the trim cover portion at the first edge, and the second cushion assembly being sewn to the trim cover portion at the second edge.

[0635] Clause 65. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the vehicle seat cushion component is included in the vehicle seat back or the vehicle seat bottom.

[0636] Clause 66. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first cushion assembly and the second cushion assembly are each independently formed by compression molding.

[0637] Clause 67. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first outer pillow cover and the second outer pillow cover each independently comprise a nonwoven fabric.

[0638] Clause 68. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first outer pillow cover and the second outer pillow cover each independently comprise natural fibers.

[0639] Clause 69. The vehicle seat cushion component according to any of the foregoing or subsequent clauses also includes a central cushion component positioned in an opening defined by the trim covering portion.

[0640] Clause 70. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first core cushion portion, the second core cushion portion and the central cushion component are each independently composed of foamed polyurethane.

[0641] Clause 71. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first core cushion portion, the second core cushion portion and the central cushion component are each independently composed of a plurality of three-dimensional loops, the plurality of three-dimensional loops being composed of a thermoplastic polymer.

[0642] Clause 72. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the plurality of three-dimensional loops includes a plurality of fused joints in which two of the loops are attached to each other.

[0643] Clause 73. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein at least a subset of the loops in a plurality of three-dimensional loops are not parallel or misaligned with each other.

[0644] Clause 74. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first core cushion portion, the second core cushion portion and the central cushion component independently contain 60% to 95% air by volume.

[0645] Clause 75. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first core cushion portion, the second core cushion portion, and the central cushion component each independently have approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0646] Clause 76. Vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0647] Clause 77. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, 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.

[0648] Clause 78. Vehicle seat cushion components according to any of the foregoing or subsequent clauses, wherein the thermoplastic polymer is a biodegradable or recyclable polymer.

[0649] Clause 79. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein a plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex.

[0650] Clause 80. Vehicle seat cushion components pursuant to any of the foregoing or subsequent clauses may also include those providing sound insulation and temperature cushioning.

[0651] Clause 81. A vehicle seat, in combination or not in combination with any of the foregoing 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 including 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 including a first core cushion portion surrounded by a first outer cushion cover, the first outer cushion cover being surrounded by a first cushion trim cover; a second cushion assembly including a second core cushion portion surrounded by a second outer cushion cover, the second outer cushion cover being surrounded by a second cushion trim cover; and a trim cover portion having a first edge and a second edge, the first cushion assembly being sewn to the trim cover portion at the first edge, and the second cushion assembly being sewn to the trim cover portion at the second edge.

[0652] Clause 82. A vehicle seat pursuant to any of the foregoing or subsequent clauses, wherein the first outer pillow cover and the second outer pillow cover each independently comprise a nonwoven fabric.

[0653] Clause 83. A vehicle seat pursuant to any of the foregoing or subsequent clauses, wherein the first outer pillow cover and the second outer pillow cover each independently comprise natural fibers.

[0654] Clause 84. A vehicle seat according to any of the foregoing or subsequent clauses, wherein the vehicle seat cushion component further includes a central cushion component positioned in an opening defined by the trim covering portion.

[0655] Clause 85. A vehicle seat according to any of the foregoing or subsequent clauses, wherein the first core padding portion, the second core padding portion and the central padding component are each independently made of foamed polyurethane.

[0656] Clause 86. A vehicle seat according to any of the foregoing or subsequent clauses, wherein the first core padding portion, the second core padding portion and the central padding component are each independently composed of a plurality of three-dimensional loops, the plurality of three-dimensional loops being composed of a thermoplastic polymer.

[0657] Clause 87. A vehicle seat according to any of the foregoing or subsequent clauses, wherein the plurality of three-dimensional wire loops includes a plurality of fused joints in which two of the loops are attached to each other.

[0658] Clause 88. A vehicle seat according to any of the foregoing or subsequent clauses, wherein at least a subset of the loops in a plurality of three-dimensional silk loops are not parallel or aligned with each other.

[0659] Clause 89. A vehicle seat according to any of the foregoing or subsequent clauses, wherein the first core padding portion and the second core padding portion contain 60% to 95% air by volume.

[0660] Clause 90. A vehicle seat according to any of the foregoing or subsequent clauses, wherein the first core padding portion and the second core padding portion each independently have approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0661] Clause 91. Vehicle seat according to any of the foregoing or subsequent clauses, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0662] Clause 92. A vehicle seat cushion component, in combination with or without any of the foregoing or subsequent clauses, the vehicle seat cushion component comprising: a plastic mesh base including a plurality of three-dimensional loops made of a thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first surface and a second surface; a first foam pad attached to the plastic mesh base at the first edge; and a second foam pad attached to the plastic mesh base at the second edge.

[0663] Clause 93. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the vehicle seat cushion component is included in the vehicle seat back or the vehicle seat bottom.

[0664] Clause 94. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the plurality of three-dimensional loops includes a plurality of fused joints in which two of the loops are attached to each other.

[0665] Clause 95. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first foam cushion and the second foam cushion are each independently composed of a foamed polymer.

[0666] Clause 96. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first foam cushion and the second foam cushion are each independently composed of foamed polyurethane.

[0667] Clause 97. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the first foam cushion and the second foam cushion are each at least partially disposed above the first surface.

[0668] Clause 98. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein a first foam pad is attached to a first edge and a second foam pad is attached to a second edge.

[0669] Clause 99. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein a first foam cushion is attached to a plastic mesh base using a first retaining clip, and a second retaining clip is attached to the plastic mesh base, the first retaining clip and the second retaining clip each having an end embedded in the foam of the first foam cushion or the second foam cushion, and a retaining clip end attached to the plastic mesh base.

[0670] Clause 100. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein at least a subset of the loops in a plurality of three-dimensional loops are not parallel or misaligned with each other.

[0671] Clause 101. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the rings in a plurality of three-dimensional silk loops are randomly oriented.

[0672] Clause 102. Vehicle seat cushion components according to any of the foregoing or subsequent clauses, wherein the plastic mesh base contains 60% to 95% air by volume.

[0673] Clause 103. Vehicle seat cushion components according to any of the foregoing or subsequent clauses, wherein the plastic mesh base has a density of approximately 0.01 g / cm³. 3 Up to 0.200 g / cm 3 The density.

[0674] Clause 104. Vehicle seat cushion components according to any of the foregoing or subsequent clauses, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0675] Clause 105. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, 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.

[0676] Clause 106. Vehicle seat cushion components according to any of the foregoing or subsequent clauses, wherein the thermoplastic polymer includes linear low-density polyethylene.

[0677] Clause 107. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein a plurality of three-dimensional loops have a fineness of 200 dtex to 10,000 dtex.

[0678] Clause 108. A vehicle seat cushion component, in combination with or without any of the foregoing or subsequent clauses, the vehicle seat cushion component comprising: a plastic mesh base comprising a plurality of three-dimensional loops made of a thermoplastic polymer.

[0679] Clause 109. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the vehicle seat cushion component is included in the vehicle seat back or the vehicle seat bottom.

[0680] Clause 110. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the plurality of three-dimensional loops includes a plurality of fused joints in which two of the loops are attached to each other.

[0681] Clause 111. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, wherein the loops in a plurality of three-dimensional silk loops are randomly oriented.

[0682] Clause 112. Vehicle seat cushion components according to any of the foregoing or subsequent clauses, wherein the plastic mesh base contains 60% to 95% air by volume.

[0683] Clause 113. A vehicle seat cushion component according to any of the foregoing or subsequent clauses, 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.

[0684] Clause 114. An assembly, in combination or not in combination with any of the foregoing or subsequent clauses, comprising: at least one fabric sized to be displaced on the surface of a liner; and at least one retainer coupled to the at least one fabric along the periphery of the fabric to receive a decorative element, an actuator, a heat transfer layer, or any combination thereof.

[0685] Clause 115. Components pursuant to any of the foregoing or subsequent clauses also include padding.

[0686] Clause 116. Components according to any of the foregoing or subsequent clauses, wherein the liner also includes stranded mesh material.

[0687] Clause 117. The component according to any of the foregoing or subsequent clauses also includes a decorative cover, the decorative cover being sized to at least partially enclose the padding and at least one fabric, wherein the decorative cover is coupled to at least one retainer.

[0688] Clause 118. Components according to any of the foregoing or subsequent clauses, wherein at least one retainer includes at least one clamping ring.

[0689] Clause 119. Components according to any of the foregoing or subsequent clauses, wherein at least one retainer is not directly coupled to the gasket.

[0690] Clause 120. Components according to any of the foregoing or subsequent clauses, wherein at least one fabric further comprises a nonwoven material.

[0691] Clause 121. Components according to any of the foregoing or subsequent clauses, wherein the nonwoven material also includes jute.

[0692] Clause 122. A seat assembly comprising: a seat base; a seat back; and a seat trim assembly located in the seat base or seat back according to any of the foregoing or subsequent clauses.

[0693] Clause 123. A product formed by a method, with or without any of the foregoing or subsequent clauses, the method comprising: attaching at least one retainer to the periphery of at least one fabric; stacking at least one fabric on a liner; and attaching a decorative element, an actuator, a heat transfer layer, or any combination thereof to at least one retainer.

[0694] Clause 124. A product formed by a method according to any of the foregoing or subsequent clauses, the method further comprising compressing and molding at least one fabric into the outline of the pad before stacking at least one fabric on the pad.

[0695] Clause 125. A product formed by a method according to any of the foregoing or subsequent clauses, the method further comprising attaching a decorative cover, sized to at least partially surround the padding and at least one fabric, to at least one retainer.

[0696] Clause 126. A product formed by a method according to any of the foregoing or subsequent clauses, wherein stacking at least one fabric on a pad further comprises stacking at least one fabric on a twisted mesh pad.

[0697] Clause 127. A product formed by a method pursuant to any of the foregoing or subsequent clauses, the method further comprising not directly attaching at least one retainer to the gasket.

[0698] Clause 128. A product formed by the method according to any of the foregoing or subsequent clauses further includes clamping at least one clamping ring to the fabric as at least one retainer.

[0699] Clause 129. A seat assembly comprising: a seat base; a seat back; and a product located in the seat base or seat back in accordance with any of the foregoing or subsequent clauses.

[0700] Clause 130. A method, in combination or not in combination with any of the foregoing or subsequent clauses, comprising: attaching at least one retainer to the periphery of at least one fabric; stacking at least one fabric on a pad; and attaching a decorative element, an actuator, a heat transfer layer or any combination thereof to at least one retainer.

[0701] Clause 131. The method according to any of the foregoing or subsequent clauses further includes at least partially enclosing the padding and at least one fabric by attaching the decorative cover to at least one retainer.

[0702] Clause 132. The method according to any of the foregoing or subsequent clauses, wherein at least one fabric further comprises a nonwoven material.

[0703] Clause 133. A decorative component manufactured by a method pursuant to any of the foregoing or subsequent clauses.

[0704] Clause 134. A pad, in combination with or without any of the foregoing or subsequent clauses, the pad comprising: a member comprising a stranded mesh material defining a first end region and a second end region, the first end region and the second end region being defined 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.

[0705] Clause 135. A liner according to any of the foregoing or subsequent clauses, wherein the component is formed solely of a stranded mesh material.

[0706] Clause 136. The padding according to any of the foregoing or subsequent clauses, wherein the stranded mesh material comprises a polymer mesh having a plurality of integrated polymer strands.

[0707] Clause 137. A padding according to any of the foregoing or subsequent clauses, wherein a first end region is shaped to define a seat back padding; and wherein a second end region is shaped to define a seat base padding.

[0708] Clause 138. A liner according to any of the foregoing or subsequent clauses, wherein the member further includes a first surface for supporting an occupant on the liner and a second surface opposite to 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.

[0709] Clause 139. A liner according to any of the foregoing or subsequent clauses, wherein the member defines one or more channels, each channel intersecting one of the first surface and the second surface.

[0710] Clause 140. A liner according to any of the foregoing or subsequent clauses, wherein the channel extends laterally across the member and is positioned between the first end region and the second end region.

[0711] Clause 141. A padding according to any of the foregoing or subsequent clauses, wherein the channel comprises a first surface and a second surface, wherein the first surface and the second surface mate with each other.

[0712] Clause 142. The gasket according to any of the foregoing or subsequent clauses further includes one or more channel fasteners that connect the first face to the second face to retain the first end region at a non-zero angle relative to the second end region.

[0713] Clause 143. The padding pursuant to any of the foregoing or subsequent clauses may also include one or more auxiliary members supported by the member.

[0714] Clause 144. The padding according to any of the foregoing or subsequent clauses, wherein the auxiliary component comprises a stranded mesh material.

[0715] Clause 145. A liner according to any of the foregoing or subsequent clauses, wherein the auxiliary member extends outward from at least one of the first end region and the second end region of the member.

[0716] Clause 146. The gasket according to any of the foregoing or subsequent clauses also includes one or more auxiliary member fasteners for connecting the auxiliary member to the member.

[0717] Clause 147. A padding according to any of the foregoing or subsequent clauses, wherein an auxiliary member is shaped and positioned on the member to form a side cushion or lumbar support.

[0718] Clause 148. A seat assembly comprising: a frame; and a cushion supported by the frame according to any of the foregoing or subsequent clauses.

[0719] Clause 149. An instrument comprising: a die defining a series of orifices, the series of orifices being arranged to extrude material for a stranded mesh material member for padding according to any of the preceding or subsequent clauses, the series of orifices being arranged to define an outer periphery of the member, the outer periphery including a seat back area and a seat base area.

[0720] Clause 150. A tool according to any of the foregoing or subsequent clauses, wherein a series of orifices are further arranged such that the outer perimeter defines one or more channels for the component.

[0721] Clause 151. An instrument according to any of the foregoing or subsequent clauses, wherein a series of orifices are arranged such that one or more channels are positioned between the seat back area and the seat base area.

[0722] Clause 152. A method, in combination or not in combination with any of the foregoing or subsequent clauses, comprising: positioning a first end region of a stranded mesh member at a non-zero angle relative to a second end region of the member; and holding the first end region at a non-zero angle relative to the second end region.

[0723] Clause 153. The method according to any of the foregoing or subsequent clauses also includes forming a stranded mesh material component by extruding material through a die.

[0724] Clause 154. The method according to any of the foregoing or subsequent clauses, wherein the stranded mesh material component is extruded to form a first end region and a second end region.

[0725] Clause 155. The method according to any of the foregoing or subsequent clauses, wherein forming the stranded mesh material component further includes discharging the extruded material from the die through a funnel.

[0726] Clause 156. The method according to any of the foregoing or subsequent clauses also includes the material extruded after discharge via one or more rollers.

[0727] Clause 157. The method according to any of the foregoing or subsequent clauses further includes forming one or more channels during at least one of extruding the material, discharging the extruded material, and moving the extruded material.

[0728] Clause 158. The method according to any of the foregoing or subsequent clauses also includes cutting one or more channels in the component.

[0729] Clause 159. The method according to any of the foregoing or subsequent clauses further includes inserting one or more fasteners into opposite sides of the channel and / or combining opposite sides of the channel to retain the first end region relative to the second end region.

[0730] Clause 160. The method according to any of the foregoing or subsequent clauses further includes cutting the extruded material to form an outer surface of the component, the outer surface extending across the first end region and the second end region.

[0731] Clause 161. The method according to any of the foregoing or subsequent clauses further includes bending the stranded mesh material member from the first position to the second position to orient the member.

[0732] Clause 162. The method according to any of the foregoing or subsequent clauses also includes attaching one or more auxiliary components to the component.

[0733] Clause 163. The method according to any of the foregoing or subsequent clauses also includes forming auxiliary components from stranded mesh material.

[0734] Clause 164. The method according to any of the foregoing or subsequent clauses, wherein attaching the auxiliary member to the member further includes inserting one or more fasteners into the auxiliary member and the member and / or combining the auxiliary member with the member.

[0735] Clause 165. The method according to any of the foregoing or subsequent clauses also includes attaching the component to the frame of the seat assembly to provide padding for the frame of the seat assembly.

[0736] Clause 166. Any combination of any of the preceding clauses 1-165.

[0737] While various embodiments have been described above, this does not mean that these embodiments describe all possible forms according to this disclosure. In this regard, the language used in this specification is descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of this disclosure. Furthermore, features of various implementation embodiments can be combined to form other embodiments according to this disclosure.

Claims

1. A seat support member (36, 38, 54, 122, 124, 136), comprising: Multiple layers (40, 42, 44, 46, 48, 50, 52, 130, 132, 134, 138, 140) or regions of a plastic mesh, characterized in that the multiple layers (40, 42, 44, 46, 48, 50, 52, 130, 132, 134, 138, 140) or regions are stacked or attached to each other, or the multiple regions are positioned relative to each other at a non-zero angle; and A stranded mesh material component (642) includes a first surface (654), a second surface (656), and one or more channels (662) intersecting one of the first surface (654) and the second surface (656), wherein the one or more channels (662) extend laterally across the stranded mesh material component (642).

2. The seat support member (36, 38, 54, 122, 124, 136) according to claim 1, wherein, The twisted mesh material member (642) includes a twisted mesh material as the plastic mesh, the twisted mesh material member (642) defining a first end region (650) and a second end region (652), the first end region (650) and the second end region (652) being defined by the outer periphery of the twisted mesh material member (642); and The first end region (650) is positioned at a non-zero angle relative to the second end region (652).

3. The seat support member (36, 38, 54, 122, 124, 136) according to claim 2, wherein, The stranded mesh material component (642) is formed solely from the stranded mesh material.

4. The seat support member (36, 38, 54, 122, 124, 136) according to claim 3, wherein, The stranded mesh material comprises a polymer mesh having multiple integrated polymer strands.

5. The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 2 to 4, wherein, The first end region (650) is shaped to define a seat back cushion (124); and The second end region (652) is shaped to define a seat base liner.

6. The seat support member (36, 38, 54, 122, 124, 136) according to claim 5, wherein, The stranded mesh material member (642) includes a first surface (654) for supporting an occupant on the pad and a second surface (656) opposite to the first surface (654), the first surface (654) extending across the first end region (650) and the second end region (652), and the second surface (656) extending across the first end region (650) and the second end region (652).

7. The seat support member (36, 38, 54, 122, 124, 136) according to claim 6, wherein, The channel (662) is positioned between the first end region (650) and the second end region (652).

8. The seat support member (36, 38, 54, 122, 124, 136) according to claim 7, wherein, The channel (662) includes a first surface (664) and a second surface (672), wherein the first surface (664) and the second surface (672) cooperate with each other.

9. The seat support (36, 38, 54, 122, 124, 136) according to claim 8 further includes one or more channel fasteners (668) that connect the first surface (664) to the second surface (672) to hold the first end region (650) at the non-zero angle relative to the second end region (652).

10. The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 2 to 4 and 7 to 9, further comprising an auxiliary member (648) supported by the twisted mesh material member (642).

11. The seat support (36, 38, 54, 122, 124, 136) according to claim 10, wherein, The auxiliary component (648) comprises a twisted mesh material.

12. The seat support (36, 38, 54, 122, 124, 136) according to claim 10, wherein, The auxiliary member (648) extends outward from at least one of the first end region (650) and the second end region (652) of the stranded mesh material member (642).

13. The seat support (36, 38, 54, 122, 124, 136) according to claim 10, further comprising one or more auxiliary member fasteners for connecting the auxiliary member (648) to the stranded mesh member (642).

14. The seat support (36, 38, 54, 122, 124, 136) according to claim 10, wherein, The auxiliary component (648) is shaped and positioned on the twisted mesh material component (642) to form a side cushion or lumbar support.

15. The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 1 to 4, 7 to 9, and 11 to 14, further comprising: Multiple flat layers (42, 44, 46, 48, 50) are used to mount to a seat frame and support an occupant on the seat frame, wherein the multiple flat layers (42, 44, 46, 48, 50) are stacked on top of each other, and each of the multiple stacked layers has a varying density.

16. The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 1 to 4, 7 to 9, and 11 to 14, further comprising: A first pillow assembly (332) includes a first core padding portion (334) surrounded by a first outer pillow cover (336), which is surrounded by a first pillow trim cover (338). The second pillow assembly (340) includes a second core pad portion (342) surrounded by a second outer pillow cover (344); and Decorative covering portion (350) having a first edge (352) and a second edge (354), a first pillow assembly (332) being sewn to the decorative covering portion (350) at the first edge (352), and a second pillow assembly (340) being sewn to the decorative covering portion (350) at the second edge (354).

17. The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 1 to 4, 7 to 9, and 11 to 14, further comprising: The plastic mesh base (432), the first foamed pillow (450), and the second foamed pillow (452) are provided. The plastic mesh base (432) includes a plurality of three-dimensional filament loops made of thermoplastic polymer. The plastic mesh base (432) has a first edge (442), a second edge (444), a first surface (446), and a second surface (448). The first foamed pillow (450) is attached to the plastic mesh base (432) at the first edge (442), and the second foamed pillow (452) is attached to the plastic mesh base (432) at the second edge (444).

18. The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 1 to 4, 7 to 9 and 11 to 14, further comprising at least one fabric and at least one retainer (542), the at least one fabric being sized to be displaced on the surface of the padding, the at least one retainer (542) being coupled to the at least one fabric along the periphery of the fabric to receive a trim element, actuator, heat transfer layer or any combination thereof.

19. A seat assembly (120), comprising: A substrate, the substrate being adapted to be mounted to a seat frame; and The seat support (36, 38, 54, 122, 124, 136) according to any one of the preceding claims is stacked on the substrate.

20. The seat assembly (120) according to claim 19, wherein, The substrate is formed of an elastomeric material.

21. The seat assembly (120) according to claim 19 or 20, wherein, The substrate is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride.

22. The seat assembly (120) of claim 19 or 20 further includes a seat frame, wherein the substrate is attached to the seat frame.

23. A seat assembly (120), comprising: Seat frame; and The seat support (36, 38, 54, 122, 124, 136) according to any one of claims 1 to 18 is attached to or supported by the seat frame.

24. A seat assembly (120), comprising: Seat bottom; Seat backrest; and According to any one of claims 1 to 18, the seat support (36, 38, 54, 122, 124, 136) is located at the bottom of the seat or in the seat back.

25. A tool (800, 820), comprising: A mold (730) defines a series of orifices arranged to extrude material for the stranded mesh material member of the seat support (36, 38, 54, 122, 124, 136) according to any one of claims 2 to 18, the series of orifices being arranged to define an outer periphery of the stranded mesh material member (642), the outer periphery including a seat back area and a seat base area.

26. The tool (800, 820) according to claim 25, wherein, The series of orifices are also arranged such that the outer periphery defines one or more channels (662) for the stranded mesh material member (642).

27. The tool (800, 820) according to claim 26, wherein, The series of openings are arranged such that the one or more channels (662) are positioned between the seat back area and the seat base area.

28. A method (400) for manufacturing a seat support, the method comprising: The first sub-method includes: i) Multiple layers or areas forming a plastic mesh; ii) Stack or attach the plurality of layers or regions relative to each other, or position the plurality of regions relative to each other at a non-zero angle; iii) Forming a stranded mesh material component by extruding material through a die (730), discharging the extruded material, and moving the extruded material through one or more rollers (680, 682); and iv) Forming one or more channels (662) during at least one of the processes of extruding the material, discharging the extruded material, and moving the extruded material.

29. The method (400) according to claim 28, further comprising: The first end region of the stranded mesh material component of multiple pad segments is positioned at a non-zero angle relative to the second end region of the component (3802). as well as The first end region (3804) is maintained at the non-zero angle relative to the second end region.

30. The method (400) according to claim 29, wherein, The stranded mesh material component is extruded to form the first end region (650) and the second end region (652).

31. The method (400) according to claim 28, wherein, Forming the stranded mesh material component also includes discharging the extruded material from the mold through a funnel (750).

32. The method (400) of claim 28 further comprises cutting the one or more channels in the stranded mesh material member (662).

33. The method (400) of claim 30 further comprises inserting one or more fasteners (668) into opposite sides of the channel and / or combining the opposite sides of the channel to retain the first end region relative to the second end region.

34. The method (400) of claim 30 further comprises cutting the extruded material to form an outer surface of the stranded mesh material member, the outer surface extending across the first end region and the second end region.

35. The method (400) according to any one of claims 28 to 34, further comprising bending the stranded mesh material member from a first position to a second position to orient the member.

36. The method (400) according to any one of claims 28 to 34 further includes attaching an auxiliary member (648) to the stranded mesh material member.

37. The method (400) of claim 36 further comprises forming the auxiliary member from a stranded mesh material.

38. The method (400) of claim 36, wherein attaching the auxiliary member to the first stranded mesh member further comprises inserting one or more fasteners into the auxiliary member and the first stranded mesh member and / or combining the auxiliary member to the first stranded mesh member.

39. The method (400) according to any one of claims 28 to 34 and 37 to 38, further comprising attaching the stranded mesh material member to the frame of the seat assembly (20, 120) to provide padding for the frame of the seat assembly (20, 120).

40. The method (400) according to any one of claims 28 to 34 and 37 to 38, further comprising a second sub-method, the second sub-method comprising: i) Unfold the first sheet of the first material (402); ii) Cut the first seat support layer (404) from the first sheet; iii) Mount the first seat support layer onto the substrate (406). iv) Unfold the second sheet (408) of the second material, wherein the density of the second material is less than that of the first material; v) Cut the second seat support layer (410) from the second sheet; as well as vi) Install the second seat support layer on the first seat support layer (412).

41. The method (400) according to any one of claims 28 to 34 and 37 to 38, further comprising a third sub-method, said third sub-method comprising: i) Sew the first pillow assembly to the first edge of the decorative cover portion, the first pillow assembly having a first core pad portion surrounded by a first outer pillow cover, the first outer pillow cover being surrounded by the first pillow decorative cover; as well as ii) Sew the second pillow assembly to the second edge of the decorative cover portion, the second pillow assembly having a second core pad portion surrounded by the second outer pillow cover.

42. The method (400) according to any one of claims 28 to 34 and 37 to 38, further comprising a fourth sub-method, the fourth sub-method comprising: i) Attaching a first foamed pad to a first edge of a plastic mesh substrate, the plastic mesh substrate comprising a plurality of three-dimensional loops made of a thermoplastic polymer; and ii) Attach the second foamed pillow to the second edge of the plastic mesh base.

43. The method (400) according to any one of claims 28 to 34 and 37 to 38, further comprising a fifth sub-method, the fifth sub-method comprising: i) Connect at least one retainer to the periphery of at least one fabric (2702). ii) Stack the at least one fabric on the pad (2704). as well as iii) Connecting the decorative component, actuator, heat transfer layer or any combination thereof to the at least one retainer (2706).

44. A seat support (36, 38, 54, 122, 124, 136) manufactured by the method according to any one of claims 28 to 43.

45. The method according to any one of claims 28 to 34 and 37 to 38, further comprising mounting the seat support (36, 38, 54, 122, 124, 136) to the seat frame.

46. ​​A seat assembly (120) manufactured by the method according to claim 45.

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