Method and apparatus for producing liners

Abstract

Pads, seat assemblies, apparatuses, and methods of producing the same are disclosed. The method may include heating the polymeric material to a molten state such that the polymeric material becomes a molten polymer. The molten polymer may then be introduced into various embodiments of a mold plate, such as a mold plate having a first region and a different second region. For example, one region may have more open regions with open portions and closed portions. In another embodiment, the mold plate may include slits for creating the film. A heating device may heat the molten strand after the molten strand exits the mold plate. In yet another embodiment, the cushion may be made of a body of interwoven and / or entangled polymeric strands and a bolster attached thereto. In yet another embodiment, a mold may be configured to provide a liner having regions of different hardness.

Description

Cross-references to related cases

[0001] This application is a continuation-in-part of U.S. application No. 17 / 741,639 filed on May 11, 2022, and claims the benefit of U.S. Provisional Patent Application No. 63 / 353,728 filed on June 20, 2022, U.S. Provisional Patent Application No. 63 / 357,163 filed on June 30, 2022, U.S. Provisional Patent Application No. 63 / 357,222 filed on June 30, 2022, U.S. Provisional Patent Application No. 63 / 356,539 filed on June 29, 2022, and U.S. Provisional Patent Application No. 63 / 356,526 filed on June 29, 2022, the disclosures of which are hereby incorporated by reference in their entireties. Technical Field

[0002] The present disclosure relates to methods and apparatus for producing interior trim components, such as foam-free cushions, that may be used in seat assemblies in vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] For a further understanding of the nature, objects and advantages of the present disclosure, reference should be made to the following detailed description read in conjunction with the following drawings, wherein like reference numerals represent like elements, and wherein: Figure 1 Schematic diagrams of systems and methods according to embodiments described herein are shown.

[0004] Figure 2 Shows the use of Figure 1 A die plate as part of the process is shown.

[0005] Figure 3 A die-plate arrangement according to embodiments described herein is shown.

[0006] Figure 4 Another die plate arrangement according to embodiments described herein is shown.

[0007] Figure 5 A cushion blank forming a portion of a vehicle interior component according to embodiments described herein is shown.

[0008] Figure 6 Shown is a die plate assembly and a funnel that may be used as part of a method according to embodiments described herein.

[0009] Figure 7 is a front perspective view of a vehicle seat assembly according to an embodiment; Figure 8 It is used to manufacture Figure 7 A front schematic view of a system of a seat cushion of a seat assembly.

[0010] Fig. 9 According to the implementation plan Figure 8 A top perspective view of a tool plate of a system.

[0011] Fig.10 yes Figure 8 A partial top view perspective of the system.

[0012] Fig.11 According to the implementation plan Figure 8 A top perspective view of a tool mold of a system.

[0013] Fig.12 According to the implementation plan Figure 7 A front partial perspective view of a cushion of a seat assembly.

[0014] Fig.13 yes Fig.13 A top plan view of the tool panel of the system.

[0015] Fig.14 yes Fig.13 A side view of a system of more than one strand and more than one membrane.

[0016] Fig.15 yes Fig.13 An enlarged front perspective view of the system.

[0017] Fig.16 Shown is a portion of a system including a heating arrangement according to embodiments described herein.

[0018] Fig.17 The application of a heating device to a polymer filament is shown according to embodiments described herein.

[0019] Fig.18 A cross-section of a vehicle interior component manufactured according to embodiments described herein is shown.

[0020] Fig.19 The schematic diagram shows a perspective view of a seat pad or a seat back according to an embodiment.

[0021] Fig. 20 The schematic diagram shows Fig.19 A cross-sectional front view of a seat assembly.

[0022] Fig.21 The schematic diagram shows a method according to another embodiment of the present invention. Figure 1 The components used in the method.

[0023] Fig. 22 is a perspective view of an embodiment of a seat assembly with a portion of a trim cover and liner removed.

[0024] Fig.23 is a perspective view of an embodiment of a non-foam cushion / no-foam cushion.

[0025] Fig.24 is a schematic diagram of an embodiment of a non-foam pad / no-foam pad with variable hardness / bulking density / strand size.

[0026] Fig.25 is a schematic diagram of another embodiment of a non-foam pad / no-foam pad having a hardness / bulk density / average strand size gradient.

[0027] Fig.26 is a perspective view of an embodiment of a breaker plate for dispensing resin for making a non-foam cushion / non-foam cushion.

[0028] Fig. 27 is a cross-sectional side view of an embodiment of a manufacturing system.

[0029] Fig.28 is a flow chart illustrating an embodiment of a method of producing a variable non-foam cushion using a porous plate.

[0030] Fig.29 is a top view of another embodiment of a porous plate for dispensing resin for making a non-foam gasket / non-foam gasket.

[0031] Fig.30 yes Fig.29 Cross-sectional view of a portion of a multiwell plate.

[0032] Fig.31 Is from Fig.30 Magnified view of a single well of a multiwell plate.

[0033] Fig.32 is a flow chart of a method for producing a vehicle interior component.

[0034] Fig.33 It is a flow chart of a method of manufacturing a product.

[0035] Fig.34 It is a flow chart of a method of manufacturing a product.

[0036] Fig.35 is a flow chart of a method of assembling a seat.

[0037] Fig.36 It is a flow chart of a method of forming a product.

[0038] Fig.37 is a flow chart of a method for producing a vehicle interior component.

[0039] Fig.38 is a flow chart of a method for producing a vehicle interior component.

[0040] Fig.39 is a flow chart of a method for producing a vehicle interior component.

[0041] Fig.40 is a flow chart of a method of producing a product such as a seat pad.

[0042] Fig.41 is a flow chart of a method of manufacturing a seat pad. DETAILED DESCRIPTION OF THE INVENTION

[0043] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the detailed description that follows, many specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it will be apparent to one of ordinary skill in the art that the various embodiments described may be practiced without these specific details. In other examples, well-known methods, processes, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring the various aspects of the embodiments.

[0044] It should be understood that the disclosed embodiments are merely exemplary, and that different and alternative forms are possible. The drawings are not necessarily to scale and some features may be enlarged or reduced to show the details of specific components. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for teaching those skilled in the art to implement the embodiments according to the present disclosure in various ways.

[0045] It should also be understood that, although in some cases, the terms "first," "second," etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are simply used to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact without departing from the scope of the various embodiments described. Both the first contact and the second contact are contacts, but they are not the same contact.

[0046] The terms used in the description of various embodiments herein are only for the purpose of describing specific embodiments and are not intended to be limiting. As used in the description of various embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should be further understood that the terms "includes", "including", "comprises", and / or "comprising" when used in this specification specify the presence of stated features, integers, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, and / or combinations thereof.

[0047] As used herein, the term “if” is optionally interpreted to mean “when . . . . .” or “at . . . . .” or “in response to determining . . . . .” or “in response to detecting . . . . .”, as the context requires. Similarly, the phrases “if it is determined” or “if [the condition or event] is detected” are optionally interpreted to mean “upon determining . . . . .” or “in response to determining . . . . .” or “upon detecting [the condition or event]” or “in response to detecting [the condition or event],” as the context requires.

[0048] Except in the examples, or otherwise explicitly indicated, all numerical quantities indicating the amount of material or the conditions of reaction and / or use in this description should be understood as being modified by the word "about" when describing the broadest scope of the present disclosure. Practice within the stated numerical limits is generally preferred. In addition, unless explicitly stated to the contrary: percentages, "parts of . . . . . " and ratio values ​​are by weight. The term "polymer" includes "oligomers", "copolymers", "terpolymers" and the like. Unless otherwise specified, the molecular weight provided for any polymer refers to the weight average molecular weight. The description of a group or category of materials suitable or preferred for a given purpose in conjunction with the present disclosure means that a mixture of any two or more members of the group or category is also suitable or preferred. The description of the ingredients in chemical terms refers to the ingredients when added to any combination specified in the description, and does not necessarily exclude chemical interactions between the ingredients of the mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation in this article, and applies to common grammatical variants of the abbreviations initially defined after necessary modifications. Unless expressly stated to the contrary, measurements of properties are determined by the same techniques as mentioned above or below for the same property.

[0049] As used herein, the term "and / or" means that all elements or only one element of the group may be present. For example, "A and / or B" shall mean "only A, or only B, or both A and B". In the case of "only A", the term also covers the possibility that B does not exist, that is, "only A, but not B".

[0050] It should also be understood that the present disclosure is not limited to the specific embodiments and methods described below, as specific components and / or conditions may of course vary. Furthermore, the terminology used herein is only for the purpose of describing specific embodiments of the present disclosure and is not intended to be limiting in any way.

[0051] With respect to the terms “comprising,” “consisting of,” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed subject matter may include the use of either of the other two terms.

[0052] The terms "substantially," "approximately," or "about" may be used herein to describe the disclosed embodiments or the claimed embodiments. The term "substantially" may modify a value or relative property disclosed or claimed in the present disclosure. In such cases, "substantially" may mean that the value or relative property it modifies is within ±0%, ±0.1%, ±0.5%, ±1%, ±2%, ±3%, ±4%, ±5%, or ±10% of that value or relative property.

[0053] It should also be appreciated that integer ranges include all intermediate integers explicitly. For example, integer ranges 1 to 10 include 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 explicitly. Similarly, ranges 1 to 100 include 1, 2, 3, 4 ... 97, 98, 99, 100. Similarly, when any range is required, the difference between the upper and lower limits divided by 10 as the numeral in the middle of the increment can be considered as an optional upper limit or lower limit. For example, if the range is 1.1 to 2.1, then the following numerals 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 and 2.0 can be selected as lower limit or upper limit.

[0054] After being distributed by one or more orifices of a die, plate, die plate, tool, tool plate, extrusion die or porous plate or other variations thereof, long filament or strand can be used herein to refer to substantially linear polymer units (although they can be fused together to form a mesh-like structure), which is also used to refer to equivalent components. Similarly, term: consolidated filament structure, filament structure, yield strand, main body, mesh (mesh), final member, non-foam component, nonwoven mesh or liner can refer to the same or similar parts. The term funnel and cover (cover) can also be used to refer to the same or similar parts. The description herein can also use a variety of terms to refer to holes (hole), such as holes, orifices, nozzles, apertures (aperture) etc. In another example, tank, water jug, cooling chamber, liquid tank and bath can refer to the same or similar parts. When describing different preferred embodiments, using different terms to refer to the same or similar parts can be used to avoid confusion. The terms may be interchangeable in that various components from features of various embodiments may be combined in ways not expressly described herein. This does not detract from the fact that certain terms may provide inherent details not included by other interchangeable terms unless expressly stated otherwise (e.g., a water jug ​​and a liquid jug refer to similar interchangeable components, although in at least one preferred embodiment, when a water jug ​​is used, the jug is filled with water or is arranged to be filled with water rather than any liquid).

[0055] In the refinement, the term interconnection refers to individual polymer filaments that are entangled, interwoven, bonded or otherwise bonded to form a web body. However, interconnection does not refer to polymer filaments that are made separately and then fixed together by fasteners or threads.

[0056] refer to Figure 1 , a schematic diagram of a system 10 that can be used with a method 11 according to an embodiment described herein is shown. A hopper 12 contains solid particles of a polymer material 14 to be extruded. In this embodiment, the material 14 is a linear low density polyethylene (LLDPE), although the method described herein can use different types of polymers to produce the final product as needed and effectively. The material 14 is supplied to an extruder 16 from the hopper 12. The extruder 16 melts the material 14 and conveys the material 14 to a die plate equipment 18, which includes a die plate 20. The extruder 16 can be, for example, a conventional extruder including a barrel that receives a rotatable screw. The rotation of the screw forces the material 14 to move through the barrel and helps to heat the material due to the friction generated when the screw rotates. A heating element can be disposed on the barrel and heats the polymer material 14 in the barrel.

[0057] The material 14 exits the extruder 16 at position 22 under pressure and in a molten state. Unless otherwise specified, the term "molten" as used herein means that the material is at least partially molten. This does not mean that the material must be in a completely liquid state; rather, it means that the material is not completely solid and is still able to flow through the elements of the system 10. For example, the molten material is still able to flow through the die plate 20, but it may be very viscous and begin to solidify. Once the solid particles of polymer material 14 are melted in the extruder 16, the material will begin to cool as it stops being agitated by the extruder screw and moves away from any heaters. At different points in the process 11, the material may have a higher or lower viscosity, but if it is still partially molten and able to flow - even slowly - the term "molten" applies herein.

[0058] The die plate 20 extrude the material 14 into filaments 24. More specifically, the die plate 20 has a plurality of holes 21 disposed therethrough—see, e.g. Figure 2—Melted material 14 passes through hole 21. A single filament 24 is extruded from each die plate hole. The filaments 24 fall downward from die plate 20 to funnel 26 under system pressure and gravity. Funnel 26 helps consolidate or group the filaments 24 into a more compact arrangement, wherein the filaments 24 are bent or looped, and each filament 24 contacts and is bonded to at least one other filament 24. In this embodiment, funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. More specifically, funnel 26 is narrower at funnel outlet 30 than at funnel inlet 28. Individual, separated filaments 24 enter funnel inlet 28, and then the filaments 24 are bent or looped and move into contact with each other as they accumulate and slide downward along funnel 26 toward funnel outlet 30, and a consolidated filament structure 32 leaves funnel outlet 30 and enters water tank 34. When the filaments 24 reach the funnel 26 , those filaments near the outer portion of the funnel 26 - approximately 2-3 rows - slide down the angled surface of the funnel 26 , which creates a skin on the consolidated filament structure 32 .

[0059] The water tank 34 holds water 36 and receives the consolidated filament structure 32 from the funnel 26. The water 36 performs at least two functions. First, it helps to temporarily support the consolidated filament structure 32 to prevent it from collapsing or condensing into a less open or less porous arrangement. Therefore, the water 36 provides some resistance, which causes the other bending and looping of the filaments 24 to further build the consolidated filament structure 32. Secondly, the water 36 cools the polymer filaments 24 from the outside to solidify them. When the filaments 24 leave the die plate 20, the temperature of the water 36 can be much lower than the temperature of the filaments 24, for example, it can be in the temperature of the surrounding environment around the tank 34. Although the fluid used in this embodiment is liquid water 36, in other embodiments, other types of fluids can be used.

[0060] The water tank 34 includes a variety of rollers and conveyors that help move the consolidated filamentary structure 32 through and out of the water 36. A tractor conveyor 38 is submerged in the water 36 and engages opposite sides of the consolidated filamentary structure 32 to move it away from the hopper 26 at approximately the same speed as the consolidated filamentary structure 32 leaves the hopper 26. The gap between the opposing portions of the tractor conveyor 38 is slightly narrower than the width of the consolidated filamentary structure 32 to allow the tractor conveyor 38 to better grip the consolidated filamentary structure 32. As previously described, Figure 1 is a schematic representation and has been simplified for the purpose of illustration. For example, a conveyor such as the traction conveyor 38 may be as shown in FIG. Figure 1 The components are positioned toward the front and rear of the system 10 as in the neutral orientation, rather than on the left and right sides as shown.

[0061] Another roller 40 helps keep the consolidated filamentary structure 32 submerged and helps guide it through the water 36 toward a conveyor belt 42 and a shaker table 44 positioned outside of the water tank 34. While the consolidated filamentary structure 32 is on the conveyor belt 42, the shaker table 44 vibrates the consolidated filamentary structure 32 to remove at least some of the water 36. Pressurized air may also be blown toward the consolidated filamentary structure 32, and the consolidated filamentary structure 32 may also be squeezed to remove more water 36. Finally, the consolidated filamentary structure 32 may be cut into a desired size and shape.

[0062] As described above, the filamentary structure 32 forms a stranded-mesh material that can be used, for example, as a cushioning blank for a portion of a vehicle interior component. In some cases, the filamentary structure 32 can have a rectangular cross-section that is later cut or shaped into a desired profile for its intended use. Figure 2 As shown, a mold plate such as mold plate 20 may itself be rectangular and have more than one hole 21 - for clarity, the holes 21 are not shown in FIG. Figure 2 Only a few of the holes are labeled in the figure—more than one hole 21 has a uniform diameter and "hole density". As used in this context, "hole density" is the number of holes per unit area in the mold plate 20. In some applications, it may be desirable to have a filament structure that does not have a rectangular cross-section, or that has portions that have a higher or lower density than other portions. In some embodiments, two of these features may be combined.

[0063] Figure 3 It is shown that it is possible to combine Figure 1The mold plate equipment 46 used in the described method. The mold plate equipment 46 includes a mold plate 48 and a template (template) 50. The mold plate 48 is rectangular; However, the template 50 has a predefined contour portion 51, which is the inner periphery of the template 50 in this embodiment. The template 50 is used to mask a part of the mold plate 48 to provide a filament structure-for example, a cushion blank for a vehicle seat-the filament structure has a cross section defined by a predetermined contour portion 51. In addition to providing a filament structure with a non-rectangular cross section, the mold plate equipment 46 also provides a filament structure with more than one different density. As used in this context, the "density" of the filament structure refers to the amount of material per volume. For example, in a vehicle seat, the seat bottom can include a bolster on the inner and outer sides of the seat. It may be desirable to make the bolster slightly harder than the middle part of the seat bottom where the occupant sits. A method of achieving this is to have a filament material with a higher density in the bolster area compared to the density of the filament material in the middle of the cushion.

[0064] As described above, Figure 1 The mold plate 20 shown in FIG. 1 includes holes of uniform diameter and hole density. In contrast, Figure 2 The hole density in the mold plate 48 shown in FIG. 4 is not uniform. Instead, the mold plate 48 includes a first region 54 indicated by a curved dashed line toward the left side of the figure, as shown in FIG. Figure 3 In this embodiment, the mold plate 48 includes another of the first regions 54, which is indicated by the curved dashed line toward the right side of the figure, as shown in FIG. Figure 3 As explained in more detail below, the two first regions 54 are positioned in positions corresponding to the left and right bolster regions of the seat cushion. The mold plate 48 also includes a second region 56 that is formed by Figure 3 It should be understood that the shape of the first region 54 and the shape of the second region 56 may be different in different embodiments, depending on the desired end product.

[0065] like Figure 3 As shown in FIG. 1 , each of the first regions 54 includes more than one first aperture 58, and the second regions 56 include more than one second aperture 60. In each case, for clarity, Figure 3Only a few of the holes 58, 60 are labeled. However, it should be understood that each of the first region 54 and the second region 56 may include dozens, hundreds, or more first holes 58 and second holes 60. The first holes 58 together define an open space in the first region 54. This open space can be compared to the entire area of ​​the first region 54, which defines the open space per unit area in the first region 54. In other words, the first region 54 has a closed portion defined by the mold plate material and an open portion defined by all of the first holes 58. The total open area as defined by the first holes 58 constitutes a portion of the first region 54, and when this total open area is divided by the total area occupied by the first region 54, it produces a number that can be considered as "open space per unit area." And, because this open space per unit area is in the first region 54, it can be referred to as the "first open space per unit area." Similarly, the total open area as defined by the second holes 60 in the second region 56 defines the second open space per unit area. In Figure 3 In the embodiment shown in , the first open spaces per unit area are greater than the second open spaces per unit area, which results in a higher density of filamentary material in the first region 54 compared to the second region 56 .

[0066] Another way to think about the concept of "open space per unit area" as described above is to define a ratio - specifically, the ratio of the open portion in each of the first region 54 and the second region 56 to the total portion. In other words, the ratio of the open portion of the first region - i.e., the total open area defined by the first holes 58 - to the first region 54 (total) is greater than the ratio of the open portion of the second region to the second region 56 (total). In order to achieve the difference in hole density between the first region 54 and the second region 56, several different methods can be used. For example, in one embodiment, the diameters of the holes 58, 60 can be the same, but the number of first holes 58 per unit area in the first region 54 can be different from the number of second holes 60 per unit area in the second region 56. More specifically, there can be more first holes 58 per unit area in the first region 54 than there are second holes 60 per unit area in the second region 56. Alternatively, the number of first holes 58 per unit area can be the same as the number of second holes 60 per unit area, but the first holes 58 can have a larger diameter than the diameter of the second holes 60. In either case, the total amount of polymer material per unit area flowing through first region 54 will be greater than the total amount of material per unit area flowing through second region 56. The greater amount of material will result in a filament structure having a higher density in first region 54 than in second region 56.

[0067] Figure 4 A mold plate assembly 62 is shown according to embodiments described herein. Figure 3, the mold plate assembly 62 includes a mold plate 64 and a template 66, which is configured to cover or mask a portion of the hole in the mold plate 64. The template 66 has a predefined contour portion 67, which defines the cross-section of the final product, such as a cushion for a vehicle seat. The mold plate 64 includes a mold plate 64 similar to Figure 3 4. The first and second regions 70 and 71 of the mold plate 48 are similar to those shown in FIG. 4. Also similar to the mold plate 48, the first and second regions 70 and 72 of the mold plate 64 include first and second holes 74 and 76, respectively. However, one difference from the mold plate 64 is that the mold plate 64 includes a third region 78, which is composed of Figure 4 The dashed lines that bound the small rectangle are indicated.

[0068] The third portion 78 includes more than one third hole 81 arranged to pass therethrough—again, for clarity, only some of the third holes 81 are marked. The third holes 81 together define the third open space per unit area in the third region 78. In this embodiment, the third open space per unit area is less than the second open space per unit area—in other words, the filament structure produced using the mold plate equipment 62 will have a lower density in the third region 78 than in the second region 71. This can be a convenient location for placing occupant sensors such as seat belt reminders (SBRs). The density of the third holes 81 in the third region 78 can also be defined as described above. That is, in the third region 78, the ratio of open area to total third region 78 will be less than the ratio of open area to total second region 71 in the second region 71. Although the mold plate equipment 62 includes the third region 78 and the first region 70 and the second region 71, other embodiments may not include the first region 70 of higher density, but may include only the third region 78 of lower density in the second region 71.

[0069] Figure 5 shows the use of mold plate equipment such as Figure 4 The mold plate equipment 62 shown in FIG. Figure 1 The filament structure 82 produced is described. The filament structure 82 includes three regions, each region corresponding to a corresponding region of the mold plate 64. More specifically, the filament structure 82 includes two first regions 70', where the prime (') symbol is used on the numerical label to designate the region from Figure 4 The first region 70' is the region of highest density in the filament structure 82 and corresponds to the left and right bolsters of the vehicle seat cushion. Figure 5 The filament structure 82 is shown as a front cross-sectional view of a cushion blank for a seat bottom, oriented in the middle. Figure 5As shown in FIG. 8 , the filament structure 82 has a substantially Figure 4 6 '. In the filament structure 82, the second region 72' has a lower density than the first region 70', and this lower density can provide a softer feel and more comfort for the seated occupant. The third region 78' has the lowest density and provides a location for the SBR or other occupant sensor. It may be important for this region to be particularly soft so that it is easily deflected to activate the sensor even for a light-weight occupant.

[0070] In order to maintain the desired shape of the final product, a mold plate assembly such as mold plate assembly 46 may be combined with a funnel having a corresponding geometric configuration—see e.g. Figure 1 The funnel 26 shown in FIG. Figure 6 A mold plate assembly 46 is shown, which includes a mold plate 48 and a mold plate 50. As described above in conjunction with Figure 1 As depicted, molten polymer may be forced through openings in die plate 48 to produce strands of material 84 that, after cooling thereof, will form the final product. Figure 6 Funnel 86 is shown that also includes a template 88 that is configured similarly to template 50 used with die plate 48. Template 88 used with funnel 86 helps ensure that the desired shape of the final product is maintained as strands 84 fall from die plate 48 and pass through funnel 86.

[0071] A method 650 for producing a vehicle interior component is described. The method 650 includes heating 652 a polymer material (e.g., 14) to a molten state, such that the polymer material becomes a molten polymer (e.g., Figure 1 ).

[0072] Method 650 includes introducing 654 molten polymer into a mold plate (e.g., 20, 48, and / or 64) having a first region (e.g., bolster region 54) and a second region (e.g., cushion region 56), wherein the first region (e.g., bolster region 54) includes more than one first hole (e.g., 58) therethrough, the second region (e.g., cushion region 56) includes more than one second hole (e.g., 60) therethrough, the first holes (e.g., 58) together define a first open space per unit area in the first region (e.g., 54), and the second holes (e.g., 60) together define a second open space per unit area in the second region (e.g., 56), and wherein the first open space per unit area is greater than the second open space per unit area (i.e., the bolster region has a different / higher density than the cushion region, e.g., the holes in the first region, such as 54, allow more material to pass through than the holes in the second region).

[0073] The method 650 includes cooling 656 the molten polymer after the molten polymer exits the die plate (eg, 20 , 48 , and / or 64 ).

[0074] In some embodiments, there are more first holes (eg, 58) per unit area in a first region (eg, 54) than second holes (eg, 60) per unit area in a second region (eg, 56).

[0075] In some embodiments, the first hole (eg, 58) has a diameter that is larger than the diameter of the second hole (eg, 60).

[0076] In some embodiments, cooling the polymer after it leaves the mold plate (e.g., 20, 48 and / or 64) produces a liner blank, the method further comprising masking a portion of the mold plate (e.g., 20, 48 and / or 64) with a template having a predetermined contour portion such that the liner blank has a cross-section defined by the predetermined contour portion.

[0077] In some embodiments, the second region (eg, 56 ) includes locations corresponding to locations of occupant sensors in the cushion blank (eg, a lower density region disposed adjacent to an occupant sensor that activates a seat belt reminder).

[0078] In some embodiments, the mold plate (eg, 20, 48, and / or 64) includes two first regions (eg, 54), each first region being positioned in a location corresponding to a respective bolster region of the cushion blank.

[0079] In some embodiments, the mold plate (e.g., 20, 48 and / or 64) includes a third region (e.g., 78) comprising more than one third hole (e.g., 81) therethrough, the third holes (e.g., 81) together defining a third open space per unit area in the third region (e.g., 78), and wherein the third open space per unit area is less than the second open space per unit area.

[0080] In some embodiments, a vehicle interior component is formed by the method of any of the preceding claims.

[0081] A method 650 for producing a vehicle interior component is described. The method 650 includes heating a polymer material (eg, 14) to a molten state such that the polymer material becomes a molten polymer.

[0082] Method 650 includes introducing 652 molten polymer into a mold plate (e.g., 20, 48 and / or 64), the mold plate including a first region (e.g., 54) having an open portion and a closed portion and a second region (e.g., 56) having an open portion and a closed portion, and wherein a ratio of the open portion of the first region (e.g., 54) to the first region (e.g., 54) is greater than a ratio of the open portion of the second region (e.g., 56) to the second region (e.g., 56).

[0083] The method 650 includes cooling 654 the molten polymer after the molten polymer exits the die plate (eg, 20 , 48 , and / or 64 ).

[0084] In some embodiments, the first region (e.g., 54) includes more than one first hole (e.g., 58) that defines an open portion of the first region (e.g., 54), and the second region (e.g., 56) includes more than one second hole (e.g., 60) that defines an open portion of the second region (e.g., 56), and wherein there are more first holes (e.g., 58) per unit area in the first region (e.g., 54) than second holes (e.g., 60) per unit area in the second region (e.g., 56).

[0085] In some embodiments, the first region (e.g., 54) includes more than one first hole (e.g., 58) that defines an open portion of the first region (e.g., 54), and the second region (e.g., 56) includes more than one second hole (e.g., 60) that defines an open portion of the second region (e.g., 56), and wherein the first hole (e.g., 58) has a diameter larger than the diameter of the second hole (e.g., 60).

[0086] In some embodiments, the vehicle interior component includes a cushion blank having a cross-section, and the method further includes masking a portion of the mold plate (eg, 20, 48, and / or 64) with a template having a contour defining the cross-section of the cushion blank.

[0087] In some embodiments, the mold plate (eg, 20, 48, and / or 64) includes more than one first region (eg, 54), each first region being positioned in a location corresponding to a respective bolster region of the cushion blank.

[0088] In some embodiments, the second region (eg, 56 ) includes a location configured to receive an occupant sensor in the cushion blank.

[0089] In some embodiments, the mold plate (e.g., 20, 48 and / or 64) also includes a third region (e.g., 78) having an open portion and a closed portion, and wherein the ratio of the open portion of the second region (e.g., 56) to the second region (e.g., 56) is greater than the ratio of the open portion of the third region (e.g., 78) to the third region (e.g., 78).

[0090] A mold plate assembly that can be used to produce a vehicle interior component is described. The mold plate assembly includes a plate that includes a first region (e.g., 54) and a second region (e.g., 56), the first region (e.g., 54) including more than one first hole (e.g., 58) therethrough, the second region (e.g., 56) including more than one second hole (e.g., 60) therethrough, the first holes (e.g., 58) together define a first open portion in the first region (e.g., 54), and the second holes (e.g., 60) together define a second open portion in the second region (e.g., 56), and wherein a ratio of the first open portion to the first region (e.g., 54) is greater than a ratio of the second open portion to the second region (e.g., 56).

[0091] In some embodiments, there are more first holes (eg, 58) per unit area in a first region (eg, 54) than second holes (eg, 60) per unit area in a second region (eg, 56).

[0092] In some embodiments, the first hole (eg, 58) has a diameter that is larger than the diameter of the second hole (eg, 60).

[0093] In some embodiments, the mold plate equipment also includes: a template configured to cover at least a portion of the first hole (e.g., 58), at least a portion of the second hole (e.g., 60), or at least a portion of the first hole (e.g., 58) and the second hole (e.g., 60), the template having a predetermined contour portion defining a cross-section of a portion of the vehicle interior component.

[0094] In some embodiments, the vehicle interior component is a seat cushion, and the panel includes two first regions (eg, 54), each first region being positioned in a location corresponding to a respective bolster region of the seat cushion.

[0095] Figure 7 The figure shows a seat assembly 120 as a vehicle seat assembly 120 according to an embodiment. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be used. The seat assembly 120 may be used in a land vehicle, an airplane, a boat, or the like. The seat assembly 120 may also be used as an office chair, a comfort chair, or the like.

[0096] The depicted seat assembly 120 includes a seat bottom pad 122 to support the pelvis and thighs of the seated occupant. The seat assembly 120 also includes a seat back pad 124 to support the back and shoulders of the seated occupant. The trim cover 26 is disposed on the seat pads 122, 124 to hide the pads 122, 124 and provide a uniform and smooth contact surface for the occupant.

[0097] Reference now Figure 8 , the system 127 and method of the seat pad 122, 124 are manufactured by extruding a thermoplastic resin web. In the depicted embodiment, the extruder 128 provides pressurized molten thermoplastic resin to the extrusion die 130. The extrusion die 130 is arranged with more than one outlet port or nozzle 132 to distribute more than one strand 134 of molten thermoplastic resin. The strand 134 is distributed by a tool 136 and enters a fluid chamber 138. The tool 136 guides the strand 134 into the fluid chamber 138. The fluid chamber 138 can hold a fluid, such as water, for blocking and cooling the strand 134. The fluid chamber 138 blocks the flow of the strand 134, so that the strand 134 is bent, looped and crossed with adjacent strands 134 within the profile defined by the tool 136. The strand 134 can also expand and float in the fluid chamber 138. The strands 134 are fluid cooled in the fluid chamber 138 to form the unitary nonwoven thermoplastic liner 122. According to the method, the nonwoven thermoplastic liner 122 is fluid blocked, cooled, and solidified.

[0098] Fig. 9 and Fig.10 The figure shows the tool 136 as a plate 136, referred to as a funnel plate 136. Apertures 140 are formed through the plate 136 to guide and funnel the strands 134 of thermoplastic resin into the cooling chamber 138. Figure 7 The through apertures 140 are sized to match the overall profile or perimeter of the seat bottom pad 122 when viewed in the front-to-back direction marked as Z in FIG. Thus, the molten resin strands 134 are collected, directed, and cooled into the pad 122 having the overall profile of the seat pad 122. As the strands 134 bend, loop, and cross, the plate 136 shapes the mesh of the molten resin strands 134 into the overall profile of the pad 122. The plate 136 shapes the mesh before the mesh solidifies into the nonwoven mesh component of the pad 122.

[0099] The through hole 140 is provided with a curvature to form a nonwoven pad 122 with a curvature. For example, the through hole 140 has an overall convex profile to form a concave surface 142 on the top surface of the pad 122 as a central seating surface. The through hole 140 may also include a fillet or chamfer around the aperture 140 at the input end of the plate 136. The fillet may have a radius of at least 12 mm, or the chamfer may be dimensioned to be 12 mm by 12 mm. The fillet or chamfer provides a leading edge around the aperture 140 to guide the strands 134 into the plate aperture 140.

[0100] The seat pads 122, 124 are typically molded from foam materials. Foam pads require dedicated tools to mold each pad component. Compared to the prior art molding tools, the seat pad 122 includes a dedicated tool plate 136. The system 127 includes a flexible device suitable for manufacturing a variety of pads with a variety of tool plates. The extrusion die 130 includes more than one nozzle 132 over the entire area of ​​the through hole 140. When used with the tool plate 136, the nozzles outside the periphery of the through hole 140 are closed so that the extruded strands 134 are only distributed into the pores 140. The closing operation or opening operation of each nozzle 132 can be adjusted for each tool plate 136.

[0101] The tool plate 136 induces a shape on the cushion 122 before the strands 134 cool, solidify and solidify into a nonwoven mesh cushion material. Overmolding processes that create shapes, contours, seating surfaces and connecting surfaces can be eliminated. The cushion 122 is cut from an otherwise continuously formed mesh component. Alternatively, the cushion 122 can be formed from more than one mesh component segment with an overall profile of sequential transitions that are combined within the trim cover 126. The segments can be glued or otherwise fastened together.

[0102] The tool plate 136 may have a suitable thickness in excess of 12 millimeters. For example, the tool plate 136 may have a thickness of at least one inch. Fig.11 , the tool 136 may be a tunnel mold 144 having a greater thickness than the tool plate 136. For the depicted example, the mold 144 has a thickness of six inches. The mold 144 includes a through hole 140 formed through the mold 144 in the thickness direction to guide the molten thermoplastic resin strand 134 into the fluid chamber 138.

[0103] The mold 144 also includes one or more cooling channels 146 formed into the body of the mold 144, such as Fig.11140 . The cooling channel 146 extends toward the through hole 140 to allow the coolant to cool the casting mold 144 and thus cool the mesh material in the cavity of the pore 140. The casting mold 144 can extend into the fluid of the chamber 138 so that the casting mold 144 is cooled by the fluid of the chamber 138 and the fluid is also disposed in the pore 140 to cool and form the nonwoven mesh. The cooling of the casting mold 144 begins to cool the mesh strands 134 and form the shape of the pad 122 while the strands 134 and the fluid are in the cavity of the pore 140 of the casting mold 144. The cooling of the casting mold 144 also keeps the casting mold 144 at a suitable temperature for repeated molding cycles of multiple mesh components. According to an embodiment, the cooling channel 146 does not intersect with the through hole 140. According to another embodiment, the cooling channel 146 intersects with the through hole 140 to allow the fluid to pass from the cooling channel to the cavity in the through hole 140.

[0104] A method 150 of making a product is described. The method 150 includes dispensing 152 molten thermoplastic resin through a tool (e.g., 136) having an aperture (e.g., 140) sized to fit the entire perimeter of the product, the tool (e.g., 136) producing more than one strand (e.g., 134) through the tool aperture (e.g., 140) while maintaining the more than one strand (e.g., 134) within the entire perimeter of the product.

[0105] The method 150 includes buckling 154 the strands (eg, 134) by blocking the flow of more than one strand (eg, 134), the buckled strands (eg, 134) intersecting into a unitary nonwoven body in the shape of the entire perimeter of the product.

[0106] In some embodiments, method 150 includes cooling 156 more than one strand (eg, 134) into a unitary nonwoven product.

[0107] In some embodiments, method 150 dispenses molten thermoplastic resin from more than one nozzle and closes a subset of the more than one nozzles outside the area of ​​the aperture (eg, 140), the more than one nozzles collectively comprising an area larger than the area of ​​the aperture (eg, 140).

[0108] In some embodiments, method 150 includes providing a mold plate as a tool (eg, 136 ).

[0109] In some embodiments, method 150 includes cooling the tool (eg, 136).

[0110] In some embodiments, method 150 includes providing a mold (eg, 144 ) having pores (eg, 140 ) as a tool (eg, 136 ).

[0111] In some embodiments, method 150 includes providing cooling channels (eg, 146) through the mold (eg, 144) to cool the unitary nonwoven product.

[0112] In some embodiments, method 150 includes placing the casting mold (eg, 144) in a cooling fluid that cools the unitary nonwoven product.

[0113] A product is manufactured according to method 160. The method includes dispensing 162 molten thermoplastic resin through a tool (e.g., 136) having an aperture (e.g., 140) sized to fit the entire perimeter of the product, the tool (e.g., 136) producing more than one strand (e.g., 134) through the tool aperture (e.g., 140) while retaining 163 the more than one strand (e.g., 134) within the entire perimeter of the product.

[0114] The method includes buckling 164 the strands (eg, 134) by blocking the flow of more than one strand, the buckled strands (eg, 134) intersecting into a unitary nonwoven body in the shape of the entire perimeter of the product.

[0115] In some embodiments, the product further comprises an integral nonwoven liner.

[0116] In some embodiments, the product further comprises a concave contoured perimeter.

[0117] A tool (e.g., 136) is depicted. The tool (e.g., 136) includes a tool body having a through hole (e.g., 140) sized to match the entire perimeter of the pad, the through hole (e.g., 140) being configured to receive molten thermoplastic resin as more than one dispensed strand (e.g., 134).

[0118] The tool through-holes (eg, 140) are configured to retain more than one allocated strand (eg, 134) within the entire perimeter of the pad.

[0119] In some embodiments, the through-holes (eg, 140 ) are formed into a seat pad, and the through-holes (eg, 140 ) are configured to form a unitary nonwoven pad.

[0120] In some embodiments, the through-holes (eg, 140) are formed to have a curvature, and the through-holes (eg, 140) are configured to form a unitary nonwoven mat having a curvature.

[0121] In some embodiments, a through hole (eg, 140) is provided with more than one bend having a radius of at least 12 mm.

[0122] In some embodiments, the through-holes (eg, 140) are formed with a convex perimeter to form a concave surface on the liner.

[0123] A system for manufacturing a gasket is described. The system includes a dispenser of molten thermoplastic resin. The system includes a tool (e.g., 136) oriented relative to the dispenser to receive the molten thermoplastic resin.

[0124] In some embodiments, the system also includes a fluid chamber for receiving molten thermoplastic resin to block the flow of more than one allocated strand (e.g., 134) to cause the strands (e.g., 134) to flex to intersect into a unitary nonwoven body in the shape of the entire perimeter of the pad.

[0125] In some embodiments, a tool (eg, 136) is oriented within the fluid chamber to cool more than one dispensed strand (eg, 134) into a unitary nonwoven mat.

[0126] In some embodiments, cooling channels are formed through a tool (eg, 136) to cool more than one dispensed strand (eg, 134) into a unitary nonwoven mat.

[0127] Figure 7 The figure shows a seat assembly 120 as a vehicle seat assembly 120 according to an embodiment. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be used. The seat assembly 120 may be used in a land vehicle, an airplane, a boat, or the like. The seat assembly 120 may also be used as an office chair, a comfort chair, or the like.

[0128] The depicted seat assembly 120 includes a seat bottom pad 122 to support the pelvis and thighs of the seated occupant. The seat assembly 120 also includes a seat back pad 124 to support the back and shoulders of the seated occupant. A trim cover 126 is provided on the seat pads 122, 124 to hide the pads 122, 124 and provide a uniform and smooth contact surface for the occupant.

[0129] Reference now Fig.12 , one of the seat pads 122 is partially illustrated as being disassembled from the seat assembly 120. The seat pad 122 is formed from more than one strand 228 of extruded expanded thermoplastic resin. The seat pad 122 is also formed from a layer or film 230 of extruded thermoplastic resin that is bonded to and integrally formed with the more than one strand 228.

[0130] Reference now Figure 7, the seat pads 122, 124 are made of a system 10 and method of extruding a thermoplastic resin web. The hopper 12 contains raw material to be extruded, for example as solid particles or pellets of material. The material can be provided by a plastic such as linear low density polyethylene (LLDPE). The material is supplied from the hopper 12 to the extruder 16.

[0131] The extruder 16 melts the material and delivers it to the die plate 20. In one non-limiting example, the extruder 16 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction generated when the screw rotates. The material leaves the extruder 16 under pressure and in a molten state.

[0132] The die plate 20 extrude the material into filaments 24. The die plate 20 may be provided as described below, depending on the extrusion direction relative to the final components 122, 124 produced therefrom. More specifically, the die plate 20 has a plurality of small circular through holes or through holes (through holes or apertures), through which the molten material passes. A single filament 24 is extruded from each die plate hole. The filament 24 falls downward from the die plate into a funnel 26 under system pressure and gravity, as described below. The funnel 26 may have a cross-sectional shape that is the same as or different from the shape defined by the pores in the die plate.

[0133] The funnel 26 helps consolidate or group the filaments 24 into a more compact arrangement, wherein the filaments 24 bend or loop, and each filament 24 contacts and is bonded to at least one other filament 24. The funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet. The funnel 26 is narrower at the funnel outlet 30 than at the funnel inlet 28. Individual separated filaments 24 enter the funnel inlet 28, and as they accumulate and slide down the funnel 26 toward the funnel outlet, the filaments 24 bend / loop and move into contact, and a consolidated filament structure 32 exits the funnel outlet 30 and immediately enters the pitcher.

[0134] The liquid tank 34 holds water 36 or another fluid and receives the consolidated filament structure 32 from the funnel 26. The liquid 36 in the bath 34 helps to temporarily support the consolidated filament structure 32 to prevent the filament structure from collapsing or condensing into a less open or less porous arrangement, and helps to maintain the desired porosity and density. Therefore, the liquid 36 provides some resistance, which causes additional bending and looping of the filaments 24 to further build the consolidated filament structure 32. Secondly, the liquid cools the filaments 24 from the outside to solidify the filaments 24 and prevent the filaments 24 from combining at other locations.

[0135] Tank 34 includes various rollers and conveyors, such as a drag conveyor 38, that help move the consolidated filamentary structure 32 through and out of the liquid 36. The speed of the rollers and conveyors can be controlled to move the consolidated filamentary structure 32 away from the hopper 26 at a speed that depends on the speed at which the consolidated filamentary structure 32 leaves the hopper 26.

[0136] Other rollers, such as roller 40, help keep the consolidated filamentary structure 32 submerged in the liquid 36 and guide the consolidated filamentary structure 32 through the liquid 36 toward a conveyor belt 42 and a vibrating table 44 disposed outside of the tank 34. The vibrating table 44 vibrates the consolidated filamentary mesh structure 32 while it is on the conveyor belt 42 to remove the liquid 36. Additionally or alternatively, pressurized air may be blown toward the consolidated filamentary structure 32, and / or the consolidated filamentary structure 32 may be squeezed to remove the liquid 36. The consolidated filamentary structure 32 may then be cut into a desired size and shape.

[0137] Fig.13 The figure shows a top plan view of an extrusion die 20 according to an embodiment. The extrusion die 20 includes more than one aperture or nozzle 238 formed to pass therethrough to extrude strands 228. The die 20 also includes more than one slit 244 formed to pass therethrough to extrude the film 230 simultaneously with the strands 228. The strands 228 each have a small cross section to produce an elongated material that is easy to bend, flex or otherwise combine in a variety of directions to form a mesh pattern of the liner 122. The film 230 has a cross section that is wide enough to cover most or all of the liner 22. The film 230 also has a relatively narrow thickness to provide a continuous layer 230 on the liner 122. In the depicted embodiment, the slits 244 have parallel thicknesses to provide a planar film 230. However, any cross-sectional slits 244 may be used. The slits 244 may also have a thickness greater than the diameter of the strands 228.

[0138] Fig.14 The figure shows an uninterrupted flow of molten thermoplastic resin from strands 228 and film 230 of extrusion die 20. Unless otherwise specified, the term "molten" as used herein means that the material is at least partially melted. This does not mean that the material must be in a completely liquid state; rather, it means that the material is not completely solid and is still able to flow through the elements of system 10. For example, the molten material is still able to flow through the die plate 20, but it may be very viscous and begin to solidify. Once the solid particles of polymer material are melted in the extruder 16, the material begins to cool when it stops being agitated by the extruder screw and moves away from any heaters. At different points in method 11, the material may have a higher or lower viscosity, but if it is still partially melted and able to flow—even slowly—the term "molten" applies herein.

[0139] Fig.15 Also shown is the extrusion of strands 228 and film 230 from extrusion die 20. Fig.15 , molten strands 228 and film 230 are illustrated entering the funnel plate 26 for passage to the cooling chamber 34. In the cooling chamber 34, the flow of the strands 228 is impeded by the fluid to flex, bend, and bond to each other, and to cause a subset of the strands 228 to also join and bond to the film 230. The strands 228 and film 230 are also cooled and solidified within the cooling chamber 34, so that the strands 228 and film 230 form a unitary body as the liner 122.

[0140] The membrane 230 may also bend or otherwise deform within the fluid chamber 34. For a relatively flat membrane 230, the increased thickness of the membrane 230 relative to the strands 228 is optimized to resist deformation of the membrane 230. Fig.12 , Fig.13 and Fig.14 As illustrated in FIG. 1 , one of the films 230 is formed on an outer surface of the liner 122 . Fig.13 , Fig.14 and Fig.15 Another of the membranes 230 is also illustrated as being formed within the liner 122 and between the two subsets of strands 228 .

[0141] The outer film 230 provides surface tension for a continuous seating surface across the cushion 122 similar to the skin along the foam cushion for support and comfort to the occupant. The film 230 also provides a surface for attaching other seat components by adhesives, hook and loop fasteners, or the like. Fig.12 , another layer 246 is attached to the outer film 230. According to one embodiment, the layer 246 is a trim cover. According to another embodiment, the layer 246 is an actuator, such as an airbag component. According to even another embodiment, the layer 246 is a heat transfer layer, such as a heating pad.

[0142] The membrane 230 is formed to be impermeable across the area of ​​the air permeable area of ​​the cushion 122 formed by the web of strands 228 to provide a boundary to enclose the web 228 for ventilation. Apertures 248 are formed through the membrane 230 to install vents, ducts, plenums, or the like for conveying fluid through the cushion 122 for heating or cooling the occupant. The apertures 248 are formed through the membrane 230 in a post-extrusion operation such as a stamping operation or a cutting operation.

[0143] Despite Figure 13-Figure 15The middle figure shows two parallel films 230, but any number of films 230 oriented at any angle can be formed based on the arrangement of the slots 244 in the extrusion die 20. The temperature and pressure of the extruder 16 can also be changed to change the thickness or flatness of the film 230.

[0144] The seat pads 122, 124 are typically molded from foam materials. Foam pads require dedicated tools to mold each pad component. Compared to the prior art molding tools, the seat pad 122 includes a dedicated extrusion die 20. The system 10 includes a flexible device suitable for manufacturing a variety of pads with a variety of extrusion dies 20. After a certain number of pads 122 are manufactured, the extrusion die 20 is removed from the extruder 16. Then, another extrusion die 20 is installed with a specific pore 238 and slit 244 pattern for another pad 122. Then, a certain number of second pads 122 are extruded through the second extrusion die 20.

[0145] A method 170 of forming a non-foam cushion from a film (eg, 230) is described. The method 160 includes dispensing 172 (eg, from an extruder) a molten thermoplastic resin into more than one strand (eg, 228) and at least one film (eg, 230).

[0146] Method 170 includes (e.g., using a fluid such as water) blocking 174 the flow of more than one strand (e.g., 228) distributed therefrom, the blocking causing the more than one strand (e.g., 228) to expand by interlacing and combining at least a subset of the more than one strand (e.g., 228) with each other and with at least one membrane (e.g., 230) into a unitary body.

[0147] In some embodiments, method 170 includes cooling 176 more than one strand (eg, 228) and at least one film (eg, 230) into a unitary product.

[0148] In some embodiments, method 170 includes cooling more than one strand (eg, 228) and at least one membrane (eg, 230) with a fluid, wherein flow of the more than one strand (eg, 228) is blocked by the fluid.

[0149] In some embodiments, method 170 includes cooling more than one strand in the fluid chamber (eg, 228).

[0150] In some embodiments, method 170 includes dispensing at least one film on an exterior surface of the monolithic body (eg, 230).

[0151] In some embodiments, method 170 includes distributing at least one membrane (eg, 230) between at least two subsets of more than one strand (eg, 228).

[0152] In some embodiments, method 170 includes forming pores through at least one membrane (eg, 230).

[0153] In some embodiments, dispensing further comprises dispensing more than one strand through more than one aperture in the tool (eg, 228); and dispensing at least one film through at least one slit in the tool (eg, 230).

[0154] In some embodiments, method 170 includes removing a tool from an extruder; installing a second tool to the extruder; distributing the molten thermoplastic resin into a second one or more strands (e.g., 228) and a second film (e.g., 230) through the second tool; and blocking the flow of the distributed second one or more strands (e.g., 228) by causing at least a subset of the second one or more strands (e.g., 228) to cross each other and the second film into a second monolithic body different from the first monolithic body, which blocks the flow of the second one or more strands (e.g., 228) to expand.

[0155] In some embodiments, method 170 includes assembling a seat with a cushion formed by the method.

[0156] A product is described. The product is formed by a method according to any of the preceding techniques.

[0157] A product is formed by method 170. Method 180 includes dispensing 172 molten thermoplastic resin into more than one strand (eg, 228) and at least one film (eg, 230).

[0158] Method 170 includes blocking 174 the flow of more than one strand (e.g., 228) dispensed therefrom, the blocking extending the more than one strand by intersecting at least a subset of the more than one strand (e.g., 228) with each other and with at least one membrane (e.g., 230) as a unitary body.

[0159] In some embodiments, method 170 includes forming at least one membrane (e.g., 230) on an outer surface of the monolithic body. In some embodiments, method 170 includes forming at least one membrane (e.g., 230) as an impermeable membrane (e.g., 230) between at least two subsets of more than one strand (e.g., 228).

[0160] In some embodiments, method 170 includes forming pores through at least one membrane (eg, 230).

[0161] A seat assembly is manufactured by method 180. Method 180 includes assembling 182 a seat with a cushion formed by the techniques described above.

[0162] In some embodiments, the method 180 includes attaching 184 at least one of a seat trim, an actuator, and / or a heat transfer layer to at least one film (eg, 230 ).

[0163] A product is described. The product includes an extended network of more than one interconnected thermoplastic strands (e.g., 228) and at least one thermoplastic film (e.g., 230) integrally bonded to at least a subset of the more than one strands (e.g., 228) into a unitary body.

[0164] In some embodiments, at least one membrane (eg, 230) is oriented on an exterior surface of the monolithic body.

[0165] In some embodiments, at least one membrane (eg, 230) is impermeable.

[0166] In some embodiments, at least one membrane (eg, 230) is oriented between at least two subsets of more than one strand (eg, 228).

[0167] In some embodiments, the pores extend through at least one membrane (eg, 230).

[0168] The seat assembly includes any of the above-described products as a seat pad.

[0169] In some embodiments, a seat assembly includes at least one of a seat trim, an actuator, and / or a heat transfer layer attached to at least one film (eg, 230 ).

[0170] A tool is described. The tool includes a body having more than one aperture formed therethrough and at least one slit formed therethrough to dispense molten thermoplastic resin through the more than one aperture and the at least one slit.

[0171] A system is described. The system includes: an extruder of molten thermoplastic resin; and a tool according to claim 65, the tool being mounted to the extruder to distribute the molten thermoplastic resin into more than one strand (e.g., 228) and at least one film (e.g., 230) through the tool.

[0172] refer to Figure 1, a schematic diagram of a system 10 that can be used with a method 11 according to an embodiment described herein is shown. A hopper 12 contains solid particles of a polymer material 14 to be extruded. In this embodiment, the material 14 is a linear low density polyethylene (LLDPE), although the method described herein can use different types of polymers to produce the final product as needed and effectively. The material 14 is supplied to an extruder 16 from the hopper 12. The extruder 16 melts the material 14 and conveys the material 14 to a die plate equipment 18, which includes a die plate 20. The extruder 16 can be, for example, a conventional extruder including a barrel that receives a rotatable screw. The rotation of the screw forces the material 14 to move through the barrel and helps to heat the material due to the friction generated when the screw rotates. A heating element can be disposed on the barrel and heats the polymer material 14 in the barrel.

[0173] The material 14 exits the extruder 16 at position 22 under pressure and in a molten state. Unless otherwise specified, the term "molten" as used herein means that the material is at least partially melted. This does not mean that the material must be in a completely liquid state; rather, it means that the material is not completely solid and is still able to flow through the elements of the system 10. For example, the molten material is still able to flow through the die plate 20, but it may be very viscous and begin to solidify. Once the solid particles of polymer material 14 are melted in the extruder 16, the material will begin to cool as it stops being agitated by the extruder screw and moves away from any heaters. At different points in the method 11, the material may have a higher or lower viscosity, but if it is still partially melted and able to flow—even slowly—the term "molten" applies herein.

[0174] The die plate 20 extrude the material 14 into filaments 24. A single filament 24 is extruded from each die plate hole. The filaments 24 fall downward from the die plate 20 to the funnel 26 under system pressure and gravity. The funnel 26 helps consolidate or group the filaments 24 into a more compact arrangement, wherein the filaments 24 are bent or looped, and each filament 24 contacts and is bonded to at least one other filament 24. In this embodiment, the funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. More specifically, the funnel 26 is narrower at the funnel outlet 30 than at the funnel inlet 28. Individual separated filaments 24 enter the funnel inlet 28, and then the filaments 24 are bent or looped and move into contact with each other as they accumulate and slide downward along the funnel 26 toward the funnel outlet 30, and the consolidated filament structure 32 leaves the funnel outlet 30 and enters the water tank 34. When the filaments 24 reach the funnel 26 , those filaments near the outer portion of the funnel 26 —approximately 2-3 rows — slide down the angled surface of the funnel 26 , which creates a skin on the consolidated filament structure 32 .

[0175] The water tank 34 holds water 36 and receives the consolidated filament structure 32 from the funnel 26. Water 36 performs at least two functions. First, it helps to temporarily support the consolidated filament structure 32 to prevent it from collapsing or condensing into a less open or less porous arrangement. Therefore, water 36 provides some resistance, which causes the other bending and looping of the filaments 24 to further build the consolidated filament structure 32. Secondly, water 36 cools the polymer filaments 24 from the outside to solidify them. When the filaments 24 leave the die plate 20, the temperature of the water 36 can be much lower than the temperature of the filaments 24, for example, it can be in the temperature of the surrounding environment around the tank 34. Although the fluid used in this embodiment is liquid water 36, in other embodiments, other types of fluids can be used.

[0176] The tank 34 includes a variety of rollers and conveyors that help move the consolidated filamentary structure 32 through and out of the water 36. A pull conveyor 38 is submerged in the water 36 and engages opposite sides of the consolidated filamentary structure 32 to move it away from the hopper 26 at approximately the same speed as the consolidated filamentary structure 32 exits the hopper 26. The gap between opposite portions of the pull conveyor 38 is slightly narrower than the width of the consolidated filamentary structure 32 to allow the pull conveyor 38 to better grip the consolidated filamentary structure 32. As previously described, Figure 1 is a schematic representation and has been simplified for the purpose of illustration. For example, a conveyor such as the traction conveyor 38 may be as shown in FIG. Figure 1 The components are positioned toward the front and rear of the system 10 as in the neutral orientation, rather than on the left and right sides as shown.

[0177] Another roller 40 helps keep the consolidated filamentary structure 32 submerged and helps guide it through the water 36 toward a conveyor belt 42 and a vibrating table 44 that are positioned outside of the water tank 34. While the consolidated filamentary structure 32 is on the conveyor belt 42, the vibrating table 44 vibrates the consolidated filamentary structure 32 to remove at least some of the water 36. Pressurized air may also be blown toward the consolidated filamentary structure 32, and the consolidated filamentary structure 32 may also be squeezed to remove more water 36. Finally, the consolidated filamentary structure 32 may be cut into a desired size and shape.

[0178] Fig.16 A mold plate assembly 46 is shown, which includes a mold plate 48 and a template 50, which can be used to give the final product a specific shape. Figure 1 As described, molten polymer may be forced through openings in die plate 48 to produce molten polymer filaments 52—for clarity, only the openings are shown. Fig.17Some of the polymer filaments 52 are marked in the figure—the material will form the final product after cooling. The funnel 86 also includes a template 88, which is configured similarly to the template 50 used with the die plate 48. The template 88 used with the funnel 86 helps to ensure that the desired shape of the final product is maintained as the filaments 52 fall from the die plate 48 and pass through the funnel 86.

[0179] As the filaments 52 fall from the die plate 48, they will begin to cool as the filaments 52 approach the funnel 86. Even though the filaments 52 will eventually cool in a fluid bath—see e.g. Figure 1 34--as shown in FIG. 3 , it may be desirable to keep the filaments 52 at their temperature longer before they reach the hopper 86. To achieve this result, the embodiments described herein may include the use of a heating device 90 to surround the molten polymer filaments 52 as they fall from the die plate 48 to the hopper 86. Fig.16 In the embodiment shown in FIG. 1 , the heating device 90 is a rectangular heating structure that heats the filaments 52 on four sides. It includes four heating plates 92, 94, 96, 98 that heat the entire periphery of the molten polymer filaments 52. Although the heating plates 92, 94, 96, 98 surround the filaments 52 as they fall from the die plate 48, Fig.16 They are shown with gaps between them at the four corners. In practice, it may be convenient to surround the associated filament with a heating device such as heating device 90 without any space or gap around the periphery of the filament.

[0180] The embodiments described herein contemplate the use of different types of heating equipment, including different geometric configurations, distances from associated filaments, and amounts of heat generated. For example, in some embodiments, a heating equipment such as heating equipment 90 may use radiant heat as the sole or primary source of thermal control. In other embodiments, a convection heater or some combination of a convection heater and a radiant heater may be used. Fig.16 In the embodiment shown in , the heating plates 92, 94, 96, 98 are placed between 100 millimeters (mm) and 150 mm from the outermost filaments 52. Thus, the heating equipment 90 is positioned at least 100 mm-150 mm from any filament 52. The heating equipment 90 can be operated to control the ambient temperature around the molten polymer filaments 52 to a temperature of 60°C-140°C, although in other embodiments, temperatures outside this range may be used depending on the application and desired properties of the final product. Fig.16In the embodiment shown in , the heating equipment 90, and in particular the heating plates 92, 94, 96, 98 are attached directly to the mold plate 48, although in other embodiments the heating equipment may be self-supporting or may be attached to a structure other than the associated mold plate.

[0181] When molten polymer filaments such as filaments 52 leave the die plate and before they arrive at the associated funnel, heating them may have many advantages. For example, heating equipment 90 is configured to heat the outer portion of filaments 52, and can be operated to maintain a constant temperature around the outer portion of filaments 52, so that there is uniform bonding between filaments 52. In the absence of heating equipment such as heating equipment 90, when filaments 52 fall to funnel 26, the impact of environmental conditions on filaments 52 may be different from other situations. This may lead to inconsistent bonding between filaments 52 on different parts of the final product. In contrast, by heating the entire periphery of molten polymer filaments 52, bonding can be consistently maintained. In addition, increasing heat when filaments 52 fall from die plate 48 can produce stronger bonding between filaments 52 by maintaining them at their melting temperature for a longer time or by making them melt to even larger liquid state when they travel downward. This can provide a stronger or tougher outer portion of the final product-that is, a type of "shell" can be formed-which may be desirable in some applications.

[0182] Another benefit of using a heating device such as heating device 90 is that it can be added to Figure 1 The method 11 shown in FIG. 1 works in conjunction with a second material or a "coextruded" material. Figure 1 Shown in phantom is another extruder 68 configured to receive a polymer material 70 from a hopper 72. The polymer material 70 is different from the polymer material 14, which is supplied to the extruder 16 from the hopper 12. Similar to the extruder 16, the extruder 68 heats the material 70 to a molten state and moves it to the die plate assembly 18. The material 70 may be conveniently referred to as the first material, and after it is heated, it may be referred to as the first molten polymer 70. Similarly, the material 14 may be conveniently referred to as the second material, and after it is heated, it may be referred to as the second molten polymer. Figure 1 As shown in , the extruder 68 is positioned so that it supplies the first molten polymer 70 toward the outer edge of the mold plate 20, where the first molten polymer 70 will form more than one first molten polymer filament that will at least partially surround the second polymer filament 24.

[0183] exist Fig.16The middle figure shows the relationship between the inner polymer filaments and the outer polymer filaments produced by the coextrusion system. Specifically, the molten polymer filaments 52 are made of a first molten polymer and are positioned near the outer edge of the die plate 48. In contrast, the second group of molten polymer filaments 74 - for clarity, at Fig.16 Only some of them are marked in the figure—made of the second molten polymer and positioned inwardly from the first molten polymer. With this configuration, the first molten polymer filaments 52 at least partially surround the second molten polymer filaments 74. As previously described, Fig.16 is a schematic representation of the actual process, and some elements have been removed for clarity. In reality, the area below the die plate 48 leading to the funnel 26 will be packed with much more first molten polymer filaments 52 and second molten polymer filaments 74 than shown.

[0184] Whether a single material or multiple materials are used in a coextrusion process, embodiments described herein provide advantages based on the use of heating equipment to control the temperature of the molten polymer filaments exiting the die plate. Fig.17 A single molten polymer filament 76 is shown just after leaving the die plate. More specifically, the top portion 79 of the molten polymer filament 76 is positioned just below the die plate from which it is extruded, while the bottom portion 80 of the filament 76 is positioned in a funnel such as Fig.17 In the absence of heating equipment such as Fig.17 In the case of the heating device 90 shown in FIG. 1 , the top portion 79 of the filament 76 will be much hotter than the bottom portion 80. There will be a temperature gradient between the top portion 79 and the bottom portion 80, which may or may not be uniform, depending on the environmental conditions surrounding the filament 76. However, in Fig.17 In the embodiment shown in , heating equipment 83 is positioned around the filament 76 to control the temperature of the environment and ultimately the temperature of the filament 76 itself.

[0185] although Fig.17 The heating equipment 83 is shown on only two sides of the filament 76, but it should be understood that the heating equipment 83 can be configured to surround the filament - and indeed all of the filament exiting the die plate - such as Fig.16 As described above, controlling the temperature of the molten polymer filaments as they exit the die plate can provide desirable characteristics in the final product. Fig.18 8 shows a cross-section of a consolidated filament structure 84 manufactured according to an embodiment of the systems and methods described herein. Fig.18 As shown in FIG. 8 , the consolidated filament structure 84 includes an outer portion 87 positioned around a perimeter and an inner portion 85 positioned inwardly from the outer portion 87 .

[0186] like Fig.18 As shown in FIG. 8 , the outer portion 87 is different from the inner portion 85. For example, due to the use of heating equipment such as Fig.17 In the heating equipment 90 shown in, the outer part 87 can have better combination between the individual long filaments.And, therefore, it may also be more dense.Selectively, the outer part 87 can include the first group of fused polymer filaments made of the first material, and the inner part 85 can include the second group of fused polymer filaments made of the second material that is different from the first material.In at least some embodiments, two different materials can be used in combination with the heating equipment to provide a finished product, and this finished product has the first material around the outside of the product, and this first material is also more firmly combined and more dense than the second material located inwardly from the first material.Therefore, embodiments as described herein provide system and method, and this system and method have the flexibility of controlling the property of the finished product by using different materials and thermal control.

[0187] A method 190 for producing a vehicle interior component is disclosed. The method 190 includes heating 191 a polymer material (eg, 14 and / or 70) to a molten state such that the polymer material becomes a molten polymer.

[0188] The method 190 includes introducing 192 molten polymer into a die plate (eg, 48 ) having more than one aperture disposed therethrough such that the molten polymer moves through the apertures and forms more than one molten polymer filament.

[0189] The method 190 includes surrounding 193 the molten polymer filaments with a heating apparatus (eg, 92 - 98 ) operable to apply heat to the molten polymer filaments.

[0190] The method 190 includes introducing 186 molten polymer filaments into a bath to cool the molten polymer filaments to form a consolidated filament structure.

[0191] In some embodiments, the heating apparatus (eg, 92-98) includes a rectangular heating structure to surround the molten polymer filaments as they exit the die plate (eg, 48).

[0192] In some embodiments, the mold plate (eg, 48) includes more than one side, and a heating device is attached to each side of the mold plate (eg, 48).

[0193] In some embodiments, the heating equipment is configured to control the ambient temperature surrounding the molten polymer filaments to a temperature of 60°C-140°C.

[0194] In some embodiments, the heating equipment is positioned at least 100 mm-150 mm from the molten polymer filaments.

[0195] In some embodiments, the molten polymer filaments include an outer portion (e.g., 87) disposed toward an outer edge of a mold plate (e.g., 48) and an inner portion (e.g., 85) disposed inward from the outer portion (e.g., 87), and the heating equipment is configured to heat the outer portion (e.g., 87) so that bonding between the molten polymer filaments of the outer portion (e.g., 87) is greater than bonding between the molten polymer filaments of the inner portion (e.g., 85).

[0196] In some embodiments, the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, and the method further includes introducing a second molten polymer comprising a second material into a mold plate (e.g., 48) such that the second molten polymer moves through holes in the mold plate (e.g., 48) and forms more than one second molten polymer filament.

[0197] In some embodiments, a first molten polymer is introduced into a mold plate (e.g., 48) toward an outer edge of the mold plate (e.g., 48), and a second molten polymer is introduced into the mold plate (e.g., 48) inward from the first molten polymer such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0198] A vehicle interior component is formed by any of the above techniques.

[0199] A method 194 for producing a vehicle interior component is disclosed. The method 194 includes heating 195 a first polymer material to a molten state to produce a first molten polymer.

[0200] The method 194 includes extruding 196 a first molten polymer to form more than one first molten polymer filament. The method 194 includes heating 197 the entire periphery of the first molten polymer filament. The method 194 includes cooling 198 the first molten polymer filament in a fluid bath to produce a consolidated filament structure.

[0201] In some embodiments, the first molten polymer comprises a first material, and the method further comprises extruding a second molten polymer comprising a second material to form more than one second molten polymer filament.

[0202] In some embodiments, the first molten polymer and the second molten polymer are extruded such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0203] In some embodiments, heating the entire circumference of the first molten polymer filament includes heating the first molten polymer filament on four sides of the first molten polymer filament.

[0204] In some embodiments, heating the entire circumference of the first molten polymer filaments comprises heating the first molten polymer filaments to a temperature of 60°C to 140°C.

[0205] In some embodiments, the entire circumference of the first molten polymer filaments is heated such that bonding between the first molten polymer filaments is greater than bonding between the second molten polymer filaments.

[0206] A vehicle interior component is formed by any of the above techniques.

[0207] A method 200 for producing a vehicle interior component. The method 200 includes heating 202 a polymer material to produce a molten polymer. The method 200 includes forming 204 more than one molten polymer filament from the molten polymer by extruding the molten polymer through a die plate (e.g., 48). The method 200 includes heating 206 the entire periphery of the molten polymer filament with a heating device. The method 200 includes cooling 208 the molten polymer filament in a fluid bath to form a consolidated filament structure.

[0208] In some embodiments, a heating device is attached to the mold plate (eg, 48).

[0209] In some embodiments, the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, and the method further includes introducing a second molten polymer comprising a second material into a mold plate (e.g., 48) such that the second molten polymer moves through the mold plate (e.g., 48) and forms more than one second molten polymer filament.

[0210] In some embodiments, a first molten polymer is introduced into a mold plate (e.g., 48) toward an outer edge of the mold plate (e.g., 48), and a second molten polymer is introduced into the mold plate (e.g., 48) inward from the first molten polymer such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0211] refer to Fig.19, a seat assembly 320 is shown, such as a vehicle seat assembly 320. In other examples, the seat assembly 320 can be shaped and sized to be used as a front driver seat or a front passenger seat, a second row seat, a third row seat, or other rear seats, and can include a bench-style seat, a bucket seat, or other seat styles as shown. In addition, the seat assembly 320 can be a non-foldable seat or a foldable seat, and the foldable seat can be foldable and can be folded in a cavity in the vehicle floor. In addition, the seat assembly 320 can be configured to be used with other non-vehicle applications.

[0212] The seat assembly 320 optionally includes a frame 322 or other supporting structure. The seat assembly has a seat component, and these seat components include at least a seat bottom 324 and a seat back 326. The seat bottom 324 can be sized to accommodate a seated occupant to support the pelvis and thighs of the occupant. The seat back 326 can be sized to extend upright from the seat bottom 324 to support the back of the occupant. The seat assembly can additionally have a head restraint 327, wherein the head restraint 327 is illustrated as being used only for adjacent seat assemblies. The seat bottom 324 has a seat bottom cushion 328. The seat back 326 has a seat back cushion 330. The frame 322 can include a wire suspension mat or other structure to support the cushions 328, 330.

[0213] The frame 322 provides rigid structural support for seat components such as a seat bottom 324 and a seat back 326, and can be configured as a plurality of frame members that can move relative to each other to provide adjustment of the seat assembly. The frame can be formed of stamped steel alloys, fiber reinforced polymers, or any suitable structural material. The frame 322 can also include a substrate such as a panel to support associated cushions.

[0214] One or more trim covers 332 are used to cover the seat bottom cushion 328 and the seat back cushion 330 and provide a seating surface for the seat assembly 320. The vehicle seat assembly 320 is shown without a trim cover, and the adjacent seat assembly shows a trim cover 332. In one example, the trim cover 332 covers both the cushions 328, 330. In other examples, multiple trim covers are provided to cover the seat bottom cushion and the seat back cushion. The trim cover 332 can be formed from one or more sheets of fabric, leather, artificial leather, vinyl, or other materials.

[0215] The seat cushion 340 is described in further detail below, and the description may similarly apply to the seat bottom cushion 328 or the seat back cushion 330 .

[0216] In the example shown, the seat cushion 340 includes at least one non-foam component or member 342. In one example, and as shown, the seat cushion 340 is formed only by the non-foam component 342, so that the non-foam component 342 provides all the cushioning for the seat component between the frame 322 and the decorative cover 332. In other examples, the seat cushion 340 can be formed by the non-foam component 342 and one or more foam components (such as components formed by molded polyurethane foam or other non-foam components). The seat cushion 340 can have non-foam components and foam components that are positioned to provide different areas of the cushion 340 for the seat component. Alternatively or additionally, the seat cushion 340 can have a thin layer of foam or other material that is positioned between the non-foam component 342 and the decorative cover 332 to provide additional cushioning for one or more areas of the seat component. In addition, the seat assembly 320 can have a heating pad or heating mat positioned between the cushion 340 and the decorative cover 332. By removing some or all of the conventional foam from the seat cushion 340, the seat assembly 320 may be provided with improved support and comfort, as well as reduced weight.

[0217] Fig. 20 A cross section of a non-foam component 342 according to an embodiment of the present disclosure is depicted. Advantageously, the non-foam component 342 is a vehicle seat back or a vehicle seat bottom. The non-foam component 342 includes a plastic mesh base 360. The plastic mesh base 360 ​​includes more than one three-dimensional filament loops 362 of a first shape composed of a first thermoplastic polymer. In this context, the more than one three-dimensional filament loops 362 of the first shape have a generally block shape or any shape suitable for use as a cushion. The plastic mesh base 360 ​​has a first edge 364, a second edge 366, a first face 368, and a second face 370. A first bolster 374 is attached to the plastic mesh base at the first edge 364. A second bolster 376 is attached to the plastic mesh base 360 ​​at the second edge 366. The loops are bonded to each other.

[0218] In at least one embodiment, the first bolster 374 includes a second shaped more than one three-dimensional filament loop 390 composed of a thermoplastic polymer. In this context, the second shaped more than one three-dimensional filament loop 390 has a general bolster shape or any shape suitable for use as a side bolster. In at least one embodiment, the second bolster 376 includes a third shaped more than one three-dimensional filament loop 392 composed of a thermoplastic polymer. In this context, the third shaped more than one three-dimensional filament loop 392 has a general bolster shape or any shape suitable for use as a side bolster. In at least one embodiment, the first bolster 374 and the second bolster 376 have the same shape. In at least one embodiment, as in Fig.19 As best seen in FIG. 8 , a third (front) bolster 344 may be disposed forward of the non-foam component 342 .

[0219] In one non-limiting example, the non-foam component or member 342 of the seat cushion 340 is formed from at least two different twisted mesh materials, also referred to as an entangled three-dimensional filament structure. The twisted mesh material is made of a polymer mesh having more than one integrated polymer strand. The twisted mesh material can be made from, for example, two or more linear low density polyethylene (LLDPE) materials, although other polymers and materials that are effective in providing the desired properties and functionality are contemplated. In one non-limiting embodiment, the twisted mesh material can be formed using extruded filaments of two or more 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 described in Fig. 20 Shown in a closer view.

[0220] In at least one embodiment, for example Fig. 20 As shown in , the second formed more than one three-dimensional filament loop 390 is composed of a second thermoplastic polymer different from the first thermoplastic polymer. In at least one embodiment, the third formed more than one three-dimensional filament loop 392 is composed of a second thermoplastic polymer. In another embodiment, the third formed more than one three-dimensional filament loop 392 is composed of a third thermoplastic polymer different from the first thermoplastic polymer and the second thermoplastic polymer. In yet another embodiment, the optional third bolster 344 is made of formed more than one three-dimensional filament loop, and the formed more than one three-dimensional filament loop is composed of one of the first thermoplastic polymer, the second thermoplastic polymer, or the third thermoplastic polymer or also a fourth thermoplastic polymer different from the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer.

[0221] References Fig. 20 , at least a subset of the more than one three-dimensional filament loops are not parallel or aligned with each other. In a refinement, the loops in the more than one three-dimensional filament loops are randomly oriented. The plastic mesh base is from 60 volume % to 95 volume % air. In a refinement, the plastic mesh base has from about 1.5 lbs / ft 3 -3.5 lbs / ft 3 or 24 kg / m 3 -56kg / m 3 density. In some improvements, more than one three-dimensional filament loop includes more than one fused connection or combined connection 378, in which two loops are attached to each other. In the improvement, the three-dimensional filament loop is an extruded thermoplastic polymer. Examples of thermoplastic polymers include, but are not limited to, polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In the improvement, the thermoplastic polymer includes linear low-density polyethylene. In some improvements, the three-dimensional filament loop has a fineness from 200 dtex to 10,000 dtex. In the improvement, the three-dimensional filament loop has a fineness from 200 dtex to 5,000 dtex. In another improvement, the three-dimensional filament loop has a fineness from 200 dtex to 3,000 dtex.

[0222] In at least one embodiment, the first thermoplastic polymer, the second thermoplastic polymer, the third thermoplastic polymer, and / or the fourth thermoplastic polymer can independently be any suitable thermoplastic elastomer (TPE), such as LLDPE, thermoplastic polyetherester elastomer (TPEE), thermoplastic polyurethane (TPU), styrenic thermoplastic elastomer (TPS), or thermoplastic vulcanizate (TPV). In at least one embodiment, the first thermoplastic polymer, the second thermoplastic polymer, the third thermoplastic polymer, and / or the fourth thermoplastic polymer can be varied independently of one another to provide variable density at different locations of the non-foam component 342. For example, the first bolster 374 and / or the second bolster 376 can have a higher density than the mesh base 360.

[0223] In at least one embodiment, the first thermoplastic polymer comprising the first formed more than one three-dimensional filament loop 362 is composed of LLDPE (linear low density polyethylene) having a first density, while one or more of the second thermoplastic polymer, the third thermoplastic polymer, and the fourth thermoplastic polymer comprising the second formed more than one three-dimensional filament loop 390, the third formed more than one three-dimensional filament loop 392, and the formed more than one three-dimensional filament loop, respectively, are composed of LLDPE (linear low density polyethylene) having a second density greater than the first density. In addition to or as an alternative to the varying density, the first formed more than one three-dimensional filament loop 362 is composed of a first material having a first property, while one or more of the second thermoplastic polymer, the third thermoplastic polymer, and the fourth thermoplastic polymer comprising the second formed more than one three-dimensional filament loop 390 is composed of a second material having a property different from the first property. In addition to density, other examples of different properties may include different (such as higher or lower) bonding qualities or heat resistance.

[0224] A method is provided and may be used to form member 342, assemble cushion 340, and assemble seat assembly 320. In various examples, the method may have more or fewer steps than described below, and various steps may be performed in another order, sequentially, or simultaneously.

[0225] Figure 1 The figure shows a method and manufacturing method 10 for forming a twisted mesh material member such as member 342 for cushioning 340 and used with a method according to an embodiment. The method can be used to form members for cushioning, such as member 342 described above, and can also be used to assemble seats, such as seat assembly 320. In various examples, the method can have more or fewer steps than those described below, and the various steps can be performed in another order, sequentially, or simultaneously.

[0226] refer to Figure 1 , forming a consolidated filament structure 32. The consolidated filament structure 32 may provide a twisted mesh material from which the pad 340 and member 342 described above are formed.

[0227] refer to Figure 1 The first hopper 12 contains a first material feedstock to be extruded, for example, as solid particles or pellets of the material. The first material can be provided by a plastic such as linear low-density polyethylene (LLDPE). The first material is supplied from the first hopper 12 to a first extruder 16.

[0228] A second hopper 72 is also provided, which contains a second material feedstock to be extruded, for example, as solid particles or pellets of the material. The second material may be provided by a plastic, such as a linear low density polyethylene (LLDPE) of a different grade than the LLDPE of the first material. For example, the second material may be a different grade (grade 1, grade 2, etc.) or a different type (TPEE, TPV, etc.). The second material is supplied from the second hopper 72 to the second extruder 68.

[0229] The first extruder 16 and the second extruder 72 melt the first material 14 and the second material 70, respectively, and convey the molten first material 14 and the second material 70 to the die plate 20, respectively. The molten first material and the second material do not mix with each other. Therefore, the first extruder 16 and the second extruder 72 co-extrude the first material and the second material into the die plate 130, respectively. In a non-limiting example, the extruders 16 and 72 include a barrel receiving a rotatable screw and a heating element. The rotation of the screw forces the first material 14 and the second material 70 to move through the corresponding barrel, and the friction generated when the screw rotates helps to heat the first material 14 and the second material 70. The first material 14 and the second material 70 leave the extruders 16 and 72 under pressure and in a molten state.

[0230] The die plate 20 extrude the first material and the second material into filaments 24. More specifically, the filaments include the first more than one filament 24' made of the first material; the second more than one filament 24'' and the optional third more than one filament 24''. In at least one embodiment, one or both of the second more than one filament 24'' and the third more than one filament 24'' are made of the second material. Alternatively, one of the second more than one filament 24'' and the third more than one filament 24'' can be made of the first material. Further, in at least one embodiment, the first more than one filament 24', the second more than one filament 24'' and the third more than one filament 24'' can all be made of different materials according to material type and / or grade.

[0231] The die plate 20 may be provided as described below, depending on the extrusion direction relative to the final component 342 produced therefrom. More specifically, the die plate 20 has a plurality of small circular through holes or through-holes 351 through which the molten material passes, such as Fig.21. A single filament 380, 384, 386, 388 is extruded from each die plate hole. The die plate 20 has a central portion 351 and two side portions 355 on opposite sides of the central portion 351. A first material is extruded from the central portion 351 to form a filament 384, which forms a plastic mesh base 360, and one or both of the two side portions 355 extrude a material different from the first material, such as a second material and optionally a third material, to form a first bolster 374 and a second bolster 376. The filament 140 falls downward from the die plate under pressure and gravity into the funnel 26, as described below. The funnel 26 may have a cross-sectional shape that is the same or different from the shape defined by the holes in the die plate.

[0232] The funnel 26 helps consolidate or group the filaments 380 into a more compact arrangement, wherein the filaments 380 bend or loop, and each filament 380 contacts and bonds to at least one other filament 380. The funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. The funnel 26 is narrower at the funnel outlet 30 than at the funnel inlet 28. Individual, separate filaments 380 enter the funnel inlet 28, and as they accumulate and slide down the angled surface of the funnel 26 toward the funnel outlet 30, the filaments 380 bend / loop and move into contact, creating a material skin with 2-3 rows of filaments, and a consolidated filament structure 32 exits the funnel outlet 30 and immediately enters the water tank 34.

[0233] The liquid tank 34 holds water 36 or other fluids and receives the consolidated filament structure 32 from the funnel 26. The liquid 36 in the bath 34 helps to temporarily support the consolidated filament structure 32 to prevent the filament structure from collapsing or condensing into an arrangement that is not too open or too porous, and to maintain the desired porosity and density. Therefore, the liquid 36 provides some resistance, which causes additional bending or looping of the filaments 380 to further build the consolidated filament structure 32. Secondly, the liquid 36 cools the filaments 380 from the outside to solidify the filaments 380 and prevent the filaments 380 from bonding at other locations.

[0234] Tank 34 includes various rollers and conveyors, such as a pull conveyor 38, that help move the consolidated filamentary structure 32 through and out of the liquid 36. The speed of the rollers and conveyors can be controlled to move the consolidated filamentary structure 32 away from the hopper 26 at a speed that depends on the speed at which the consolidated filamentary structure 32 leaves the hopper 26.

[0235] Other rollers, such as roller 40, help keep the consolidated filamentary structure 32 submerged in the liquid 36 and guide the consolidated filamentary structure 32 through the liquid 36 toward a conveyor belt 42 and a vibrating table 44 disposed outside of the tank 34. While the consolidated filamentary structure 32 is on the conveyor belt 42, the vibrating table 44 vibrates the consolidated filamentary structure 32 to remove the liquid 36. Additionally or alternatively, pressurized air may be blown toward the consolidated filamentary structure 32, and / or the consolidated filamentary structure 32 may be squeezed to remove the liquid 36. It should be noted that in Figure 1 Components 12, 72, 16, 20 and 26 are shown in a front view, while components 34, 38, 40, 42 and 44 and the funnel are shown from a side view for better understanding.

[0236] In one example, the consolidated filamentary structure 32 may be generally formed with two or more surfaces for the member 342 based on the shape of the mold 20 and the funnel 26. In other examples, the consolidated filamentary structure 32 may require further processing as described below to achieve the desired shape of the member 342.

[0237] The consolidated filament structure 32 is then cut into the desired size and shape to form the outer perimeter or overall shape or outer shape of the component 342. After the component 342 is formed, the seat assembly 320 can be assembled. The component 342 is attached to the frame 322 of the seat assembly to provide the cushion 340 therefor. The decorative cover 332 can be positioned on the component 342 and the cushion 340. The decorative cover 332 can be connected to the cushion 340 and / or the frame 322. In one example, the decorative cover 332 can be connected via a tie down or other fasteners.

[0238] In a variation, the three-dimensional filament loops and the optional skin layer (if present) are composed of a thermoplastic polymer.

[0239] A vehicle seat cushion component is described. The vehicle seat cushion component includes a plastic mesh base (e.g., 360) including a first one or more three-dimensional filament loops, the first one or more three-dimensional filament loops are composed of a first thermoplastic polymer, the plastic mesh base (e.g., 360) having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face.

[0240] The vehicle seat cushion component includes a first bolster attached to a plastic mesh base (e.g., 360) at a first edge, the first foamed bolster including a second one or more three-dimensional filament loops, the second one or more three-dimensional filament loops being composed of a second thermoplastic polymer different from the first thermoplastic polymer. The vehicle seat cushion component includes a second bolster attached to the plastic mesh base (e.g., 360) at a second edge.

[0241] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a second thermoplastic polymer.

[0242] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

[0243] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer and the second thermoplastic polymer.

[0244] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

[0245] In some embodiments, the vehicle seat cushion component further includes a third bolster including fourth more than one three-dimensional filament loops comprised of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0246] In some embodiments, more than one three-dimensional filament loop includes more than one fused connection where two loops are attached to each other.

[0247] In some embodiments, at least a subset of the more than one three-dimensional filament loops are not parallel or aligned with each other.

[0248] In some embodiments, the loops in more than one three-dimensional filament loop are randomly oriented.

[0249] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0250] In some embodiments, the thermoplastic polymer includes a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0251] In some embodiments, the thermoplastic polymer comprises a first linear low density polyethylene.

[0252] In some embodiments, the thermoplastic polymer includes a second linear low density polyethylene that is different from the first linear low density polyethylene.

[0253] A seat assembly is described. The seat assembly comprises a frame and a cushion according to any of the above techniques, the cushion being supported by the frame.

[0254] A tool is described. The tool comprises: a die defining a series of apertures arranged to extrude material for a twisted mesh material member for a cushion according to any one of claims 87-99, the series of apertures arranged to define an outer perimeter of the member to define a plastic mesh base (e.g., 360), a first bolster, and a second bolster.

[0255] In some embodiments, the series of gaps are further arranged such that the outer perimeter defines a bolster.

[0256] A method 210 is described. The method 210 includes extruding 212 a first thermoplastic polymer to form a plastic mesh base (e.g., 360) including a first one or more three-dimensional filament loops, the plastic mesh base (e.g., 360) having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; and extruding 214 a second thermoplastic polymer to form a first bolster attached to the plastic mesh base (e.g., 360) at the first edge, the first foamed bolster including a second one or more three-dimensional filament loops, the second thermoplastic polymer being different from the first thermoplastic polymer.

[0257] The method 210 includes extruding 216 a material to form a second bolster attached to the plastic mesh base (eg, 360 ) at a second edge.

[0258] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a second thermoplastic polymer.

[0259] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

[0260] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer and the second thermoplastic polymer.

[0261] In some embodiments, the second bolster includes a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

[0262] In some embodiments, the technology includes a third bolster including a fourth more than one three-dimensional filament loop composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0263] refer to Fig. 22, a seat assembly 400 is disclosed. In one embodiment, the seat assembly 400 includes a seat frame 402, one or more seat cushions 404, and a trim cover 406. In an improvement, the seat assembly 400 may include additional components, such as but not limited to a massage assembly, a ventilation assembly, a heating assembly, and / or a sensor assembly. In an improvement, the seat assembly 400 is a seat for a vehicle such as an automobile, a motorcycle, an airplane, a boat, and / or a train.

[0264] In one or more embodiments, one or more cushions 404 comprise a seat bottom and / or a seat back. Unlike conventional seat cushions, which are typically injection molded foam, the seat cushions of the seat assembly 400 can be non-foam web cushions, foam free web cushions, foamless web cushions, and / or nonwoven web cushions 408 of interwoven and / or entangled polymer strands 410, such as Fig.23 As shown in . Portions of the various polymer strands are entangled with portions of other polymer strands so that more than one polymer strand functions as a single unit, piece, cushion, pillow, pad, or mat. Hereinafter, this disclosure refers to it as a non-foam cushion 408 or a foam-free cushion 408. The polymer strands are any suitable polymer material, such as a thermoplastic polymer (e.g., polyolefin, polyethylene, polypropylene, polystyrene, polycarbonate, polyurethane, and / or polyvinyl chloride).

[0265] In an improvement, the foam-free pad 412 includes a first portion / segment / region / volume / area 414 having a first hardness and a second portion / segment / region / volume / area 416 having a second hardness different from the first hardness, such as Fig.23 In the embodiment of the present invention, the hardness of the cushion is measured by equivalent volume according to ASTM 3574. The first part may include a first group of interwoven / tangled polymer strands, and the second part may include a second group of interwoven / tangled polymer strands. Hereinafter, the description will refer to it as a portion of the cushion, but it may also be referred to as a section, region, volume, zone and / or group of polymer strands of the cushion. It should also be understood that, although referred to differently, these parts are connected by interwoven or tangled polymer strands.

[0266] In a variation, the first portion 414 is stiffer than the second portion 416. In another variation, the second portion 416 may be stiffer than the first portion 414. For example, the first portion 414 may be a bolster area of ​​a seat bottom and stiffer than the second portion 416, which may be a seat portion.

[0267] The non-foam pad 412 includes other portions having different hardnesses. For example, the pad 412 includes a third portion 418 having a third hardness that is different from the second hardness. In a refinement, the third hardness is the same or substantially the same as the first hardness (i.e., within manufacturing tolerances, within 1%, 1.5%, 3%, 5%, or 10%).

[0268] In one or more embodiments, the first hardness and the second hardness may differ by at least 0.5 kPa, or more preferably at least 2 kPa, or even more preferably at least 4 kPa. In a refinement, one portion has a hardness of at least 5 kPa, or more preferably at least 7.5 kPa, or even more preferably at least 10 kPa, and the other portion has a hardness of no more than 5 kPa, or more preferably no more than 4.5 kPa, or even more preferably no more than 4.0 kPa.

[0269] In a refinement, one portion has a hardness of 5 kPa to 15 kPa, or more preferably 7 kPa to 12 kPa, or even more preferably 8 kPa to 10 kPa, while the other portion may have a hardness of 1 kPa to 5 kPa, or more preferably 2 kPa to 4.5 kPa, or even more preferably 3 kPa to 4 kPa.

[0270] In yet another variation, the foam-free pad 412 has a Fig.25 The gradient hardness is illustrated by the shading in FIG. The non-foam pad 412 has a first portion 414 (e.g., the smallest shaded portion) having the lowest hardness, a second portion 416 having an intermediate hardness (i.e., a hardness between the hardness of the first portion 414 and the hardness of the third portion 416), and a third portion 418 (e.g., the darkest shaded portion) having the highest hardness. The portions therebetween may continuously increase in hardness as they become farther from the first portion 414 and closer to the third portion 416, so that there is a hardness gradient.

[0271] In an embodiment, the first portion 414 is disposed at the first end 420, and the third portion 418 is disposed at the second end 416. In an improvement, the second portion 416 may be centrally located. Alternatively, the harder portion or the softer portion may be disposed centrally, and the other of the harder portion or the softer portion may be disposed on the periphery.

[0272] In one variation, the first portion 414 may form the top of the seat bottom so that it is positioned close to the occupant, while the third portion 418 may be positioned so that it is away from the occupant. This may provide the occupant with an immediate feeling of softness and / or comfort without sacrificing long-term durability and comfort.

[0273] Different portions of the non-foam pad can be provided with different hardnesses by having different properties or characteristics. For example, the bulk density of different portions can be different. In a refinement, the bulk density is determined according to ISO 845. Any portion described above as having a greater hardness can have a greater density. For example, Fig.24 As shown in FIG. 1 , the bolster region may have a greater density than the central region. In a refinement, the bulk density may differ by at least 3.0 kg / m 3 , or more preferably at least 7.0 kg / m 3 , or even more preferably at least 10 kg / m 3 In a variant, the difference in bulk density can be 3 kg / m 3 Up to 20 kg / m 3 , or more preferably 5 kg / m 3 Up to 15 kg / m 3 , or even more preferably 6 kg / m 3 Up to 12 kg / m 3 For example, a part has a mass not greater than 60 kg / m 3 , or more preferably not more than 55 kg / m 3 , or even more preferably not more than 50 kg / m 3 Bulk density and at least 30 kg / m 3 , or more preferably at least 35 kg / m 3 , or even more preferably at least 40 kg / m 3 For example, a part may have a bulk density of 60 kg / m 3 Up to 30 kg / m 3 , or more preferably 55 kg / m 3 Up to 35 kg / m 3 , or even more preferably 50 kg / m 3 Up to 40 kg / m 3 and the other part may have a density of ±3.0 kg / m 3 , or more preferably at least 7.0 kg / m 3 , or even more preferably at least 10 kg / m 3 For example, the other part may have a density of not more than 57 kg / m 3 , or more preferably not more than 53 kg / m 3 , or even more preferably not more than 50 kg / m 3 In yet another embodiment, the other portion may have a density of at least 33 kg / m 3 , or more preferably at least 37 kg / m 3 , or even more preferably at least 40 kg / m3 For example, a part may have a density of 60 kg / m 3 Up to 33 kg / m 3 , or more preferably 60 kg / m 3 Up to 37 kg / m 3 , or even more preferably 60 kg / m 3 Up to 40kg / m 3 and the other part may have a density of 57 kg / m 3 Up to 30 kg / m 3 , or more preferably 53 kg / m 3 Up to 30 kg / m 3 , or even more preferably 50 kg / m 3 Up to 30 kg / m 3 The bulk density.

[0274] In one or more embodiments, each part has average strand diameter.The average diameter of the first part is different from the average diameter of the second part.This difference can be at least 0.2 mm, or more preferably at least 0.4 mm, or even more preferably 0.6 mm.This difference can be 0.1 mm to 3 mm, or more preferably 0.3 mm to 1.8 mm, or even more preferably 0.5 mm to 1.2 mm.In improvement, the average diameter of a part can be at least 1.1 times of the average diameter of another part, or more preferably at least 1.5 times of the average diameter of another part, or even more preferably at least 2 times.In other words, the average diameter of a part can be 110% of the average diameter of another part, or more preferably 150%, or even more preferably 200%.For example, in an embodiment, a part has at least 1.2 mm, or more preferably at least 1.4 mm, or even more preferably at least 1.6 mm, and another part has an average diameter not more than 1.2 mm, or more preferably not more than 1.0 mm, or even more preferably not more than 0.8 mm. In a refinement, one portion may have an average diameter of 0.05 mm to 10 mm, or more preferably 0.1 mm to 5 mm, or even more preferably 0.5 mm to 1.2 mm, while another portion has an average diameter of 0.8 mm to 15 mm, or more preferably 1.2 mm to 13 mm, or even more preferably 1.6 mm to 10 mm.

[0275] In yet another embodiment, Figure 24-25 As shown in , the third portion 303 has a bulk density and / or average diameter different from the first portion and / or the second portion. In an improvement, the bulk density and / or average diameter may be the same or substantially the same as the first portion (i.e.， In some embodiments, the second portion may be disposed between the first portion and the third portion. In other embodiments, the first portion may have the smallest bulk density and / or average diameter, while the third portion has the largest bulk density and / or average diameter (i.e., the third portion is larger than the second portion and the second portion is larger than the first portion) or vice versa.

[0276] In another embodiment, the first portion, the second portion, and / or the third portion may have strands of different shapes, such as circles, squares, triangles, stars, or a variety of other shapes. When the shape is not circular, the diameter may refer to the maximum diameter of the transverse (as opposed to longitudinal) cross section of the strand to distinguish the relative sizes of the various strands. For example, in one embodiment, the first group of strands may be circular and the second group of strands may be polygonal (e.g., ， rectangle).

[0277] The seat frame 402 can be made of a rigid material such as metal, plastic, wood, or a combination thereof. The seat frame 402 can support the foam-free pad 404, other seat components (e.g., massage components, ventilation components, electronic components, etc.), and / or an occupant. For example, an aluminum seat frame 402 can be used.

[0278] In one or more embodiments, a decorative cover 406 is disposed on one or more cushions 404 and / or seat frame 402. The decorative cover 406 is arranged to contact an occupant. For example, the decorative cover 406 may be made of leather, artificial leather, polyurethane and / or polyester.

[0279] refer to Fig.26 , a die 500 such as a porous plate can be used to distribute the polymer resin into polymer strands. In an improvement, as Fig. 27 As shown in , mold 500 is an interchangeable component of dispensing system 600, so that different molds can be used to provide pads with different characteristics and properties (e.g., shape, hardness, bulk density, average strand diameter). Fig.24 As shown in , a first mold can produce a cushion having a harder bolster area and a softer center seat area, and a second mold can produce a cushion having a gradient hardness from a first surface to a second surface, as shown in Fig.25 as shown in .

[0280] The mold 500 includes a solid body 502 defining more than one orifice 504. In one or more embodiments, the more than one orifice 504 may include at least 50 orifices, or more preferably at least 500 orifices, or even more preferably at least 1000 orifices. For example, Fig.29The figure shows a die having at least 1200 orifices. Figure 30-Figure 31 The figure shows Fig.29 . As shown, each orifice can taper from a larger orifice to a smaller orifice, which can produce a greater pressure for dispensing a flowable polymer strand from a mold. The dispensing system 600 applies pressure so that the polymer resin 602 is distributed through the orifice 504 of the mold 500. Therefore, the size, arrangement, distribution and density of the orifice 504 will affect the characteristics and / or attributes of the liner, such as overall shape, hardness, bulk density, average strand diameter and strand shape. In an improvement, more than one orifice 504 includes at least a first group of orifices 506 having a size, distribution, density and / or shape different from the size, distribution, density and / or shape of the second group of orifices 508. In a modification, the third group of orifices 510 has a size, distribution, density and / or shape different from the size, distribution, density and / or shape of the first group of orifices and / or the second group of orifices.

[0281] Each group of orifices has an average diameter and an orifice density (i.e., a first group of orifices having a first average diameter and a first orifice density, a second group of orifices having a second average diameter and a second orifice density, and a third group of orifices having a third average diameter and a third orifice density). In refinements, the first average diameter may be different from the second average diameter and / or the third average diameter, and / or the first orifice density may be different from the second average density and / or the third average density. In variations, the first average diameter and / or the first orifice density and the third average diameter and / or the third orifice density are the same or substantially the same (i.e., ， Within manufacturing tolerances, within 1%, 1.5%, 3%, 5%, or 10%). In another variation, the first average diameter can be smaller than the second average diameter, and the second average diameter is smaller than the third average diameter. Alternatively or in combination, the first aperture density can be smaller than the second aperture density, and the second aperture density can be smaller than the third aperture density.

[0282] In improvement, the first average diameter is at least 1.2 mm, more preferably at least 1.4 mm, or even more preferably at least 1.6 mm. For example, the first average diameter can be 0.8 mm to 10 mm, or more preferably 1 mm to 5 mm, or even more preferably 1.2 mm to 3 mm. In some embodiments, the first aperture density can be at least 11.5 apertures / square inch, or more preferably at least 13 apertures / square inch, or even more preferably at least 15 apertures / square inch. For example, the first aperture density can be 10 to 20 apertures / square inch, or more preferably 11 to 18 apertures / square inch, or even more preferably 12 to 16 apertures / square inch. Alternatively, the first average diameter can be no more than 1.2 mm, or more preferably no more than 1.0 mm, or even more preferably no more than 0.8 mm. For example, the first average diameter may be 0.05 mm to 1.2 mm, or more preferably 0.3 mm to 1.0 mm, or even more preferably 0.7 mm to 0.9 mm. In some embodiments, the first pore density may be no more than 11.5 pores / square inch, or more preferably no more than 10 pores / square inch, or even more preferably no more than 8 pores / square inch. For example, the first pore density may be 1 to 11.5 pores / square inch, or more preferably 3 to 10 pores / square inch, or even more preferably 5 to 8 pores / square inch.

[0283] In an improvement, the second average diameter is at least 0.8 mm, more preferably at least 0.9 mm, or even more preferably at least 1.0 mm and not more than 1.6 mm, or more preferably not more than 1.5 mm, or even more preferably not more than 1.4 mm. For example, the second average diameter is 0.8 mm to 1.6 mm, or more preferably 0.9 mm to 1.5 mm, or even more preferably 1.0 mm to 1.4 mm. In some embodiments, the second orifice density is at least 9 orifices / square inch, or more preferably at least 10 orifices / square inch, or even more preferably at least 11 orifices / square inch and no more than 14 orifices / square inch, or more preferably no more than 13 orifices / square inch, or even more preferably 12 orifices / square inch. For example, the second orifice density is 9 to 14 orifices / square inch, or more preferably 10 to 13 orifices / square inch, or even more preferably 11 to 12 orifices / square inch.

[0284] In an improvement, the third average diameter is at least 1.2 mm, more preferably at least 1.6 mm, or even more preferably at least 1.8 mm. For example, the third average diameter can be 1.2 mm to 10 mm, or more preferably 1.6 mm to 8 mm, or even more preferably 1.8 mm to 5 mm. In some embodiments, the third aperture density can be at least 11.5 apertures / square inch, or more preferably at least 13 apertures / square inch, or even more preferably at least 15 apertures / square inch. For example, the third aperture density can be 10 to 20 apertures / square inch, or more preferably 11 to 18 apertures / square inch, or even more preferably 12 to 16 apertures / square inch.

[0285] In a variation, the orifices may form one or more gradients relative to their distribution (i.e., orifice density) and / or size (e.g., average diameter). The gradient may correspond to the gradient described above with respect to the pad. For example, the orifices near the first end of the mold 500 may be larger, and the size may be continuously reduced as they become further away from the first end and closer to the second end where the smallest orifice is located. Alternatively, the orifices at the periphery may be smaller, while the orifices in the central orifice or middle portion may be larger. In another example, the first group of orifices near the first end of the mold 500 may be more concentrated or arranged to have a greater orifice density, and the concentration or orifice density may be continuously reduced as they become further away from the first end and closer to the second end where the least concentrated orifices or the lowest orifice density occur. Alternatively, the orifices at the periphery may be less concentrated or have a lower orifice density than the orifices at the center or middle portion.

[0286] refer to Fig. 27 , the die 500 is arranged in the dispensing system 600. In an embodiment, the dispensing system 600 includes an inlet 601, such as a hopper for receiving a polymer resin 602, such as in a solid granulated form. In an improvement, the polymer resin 602 is sheared and heated, such as by an extruder 604, which melts the solid polymer resin 602 into a flowable form, such as a molten polymer resin 602, before dispensing the solid polymer resin 602 from the die 500. In an embodiment, the extruder 604 can be driven by a motor 606 and a transmission 608. In an improvement, the extruder 604 includes a screw 612 disposed in a barrel 614. In one or more embodiments, the die 500 is disposed and / or arranged at the end of the extruder 604 so that the die 500 can be easily removed and replaced by another die.

[0287] refer to Figure 8, a flowable molten polymer resin 131 is dispensed from the die 500 as strands and flows linearly into and through a first medium 135 such as air, and then into a second medium 139 such as water. In an improvement, the first medium 135 and the second medium 139 have different densities so that the deflection occurs at or near the medium interface 137 (i.e., the linear strands change direction). For example, the second medium 139 may have a density greater than that of the first medium 135. In a variation, the second medium 139 is cooled to a temperature below the melting point and / or glass transition temperature of the polymer resin. In an improvement, the second medium 139 may also have a heat capacity greater than that of the first medium 135. When accompanied by the cooling effect of the second medium 139, the deflection or change of direction may result in entanglement and / or interweaving of the polymer strands. The polymer strands may solidify so that the entangled / interwoven mass is a single piece, component, unit and / or generally maintains its shape, such as in the form of a pad. In one or more embodiments, the tangled / interwoven mass of polymer strands can exhibit elastic properties similar to foam and / or fabric. In an improvement, the tangled / interwoven mass can be cleaned and / or dried after being removed from the second medium 139. Once hardened, the strands can generally be fixed in position relative to each other so that they can become closer or farther depending on the pressure applied to them, but generally do not change position relative to each other. Therefore, a portion with a larger bulk density and / or larger size can exhibit a larger overall hardness, and a portion with a smaller bulk density and / or size can exhibit a smaller overall hardness.

[0288] A method 800 of manufacturing a seat cushion or seat pad is disclosed, such as Fig.28 In one or more embodiments, method 800 includes dispensing more than one polymer strand from a die into and through a media interface to form a cushion (i.e., step 810), removing the cushion from a second media (i.e., step 820), and drying the cushion (i.e., step 830). In an improvement, as Figure 8 As shown, distribution is performed by an extruder. The extruder is configured to receive a polymer resin, such as a thermoplastic polymer resin. In a variation, the extruder includes a hopper for receiving the polymer resin. For example, pellets or beads of the polymer resin can be loaded into the hopper. The hopper can guide the polymer resin into a chamber / barrel and can engage a drive such as a screw to shear the polymer resin. In an improvement, the chamber / barrel and / or portions thereof are heated. The combination of shearing and heating makes the solid granulated polymer resin a flowable molten polymer material. For example, the chamber / barrel is heated to a temperature exceeding the melting point of the resin.

[0289] The molten polymer strands can be distributed into a first medium such as air. In an improvement, the strands are distributed from a die such as a porous plate having parts with different orifice densities and / or orifice sizes. In a variation, the porous plate includes a gradient, such as an orifice density gradient and / or an orifice size gradient. In an improvement, the porous plate is an interchangeable component of the extruder, so that a first die / porous plate for making more than one first component is exchanged with a second die / porous plate for making more than one second component different from the first more than one component. The die 500 can be arranged so that gravity further guides the polymer strands into the second medium in a linear motion. In an improvement, the second medium is denser than the first medium. The medium defines a medium interface therebetween. For example, the first medium can be a gas, and the second medium can be a liquid, such as water. The difference may cause the polymer strands to deflect (e.g., bend) at or near the medium interface. The random deflection of a variety of polymer strands causes the entanglement of more than one polymer strand. The interwoven and entangled polymer strands also harden when they are cooled by the second medium and transitioned from their molten state. In an improvement, a mass of hardened interwoven / tangled polymer strands can form a non-foam cushion / no-foam cushion. In a variation, the mass (e.g., cushion) is removed from the second medium and dried. In view of the different characteristics of the parts of the mold, the cushion can have different properties, such as harder areas and softer areas. In an improvement, the different hardnesses are the result of different packing densities and / or strand diameters.

[0290] A foam-free seat pad is described. The foam-free seat pad includes more than one interwoven polymer strands, the more than one interwoven polymer strands having a first group of interwoven polymer strands having a first hardness and a second group of interwoven polymer strands having a second hardness different from the first hardness, wherein the first group of interwoven polymer strands and the second group of interwoven polymer strands are connected.

[0291] In some embodiments, a first set of interwoven polymeric strands has a first average diameter and a second set of interwoven polymeric strands has a second average diameter different than the first average diameter.

[0292] In some embodiments, the first set of interwoven polymeric strands defines a first packing density and the second set of interwoven polymeric strands has a second packing density different than the first density.

[0293] In some embodiments, the first hardness is less than the second hardness, and the first hardness is no greater than 5 kPa.

[0294] In some embodiments, the second hardness is at least 5 kPa.

[0295] In some embodiments, the foam-free seat pad also includes a third group of interwoven polymer strands having a third hardness from more than one interwoven polymer strands, and the second group of interwoven polymer strands is arranged between the first group of interwoven polymer strands and the third group of interwoven polymer strands such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

[0296] In some embodiments, more than one interwoven polymer strands form a stiffness gradient from a first region of the pad to a second region of the pad.

[0297] A vehicle seat assembly (eg, 400) is described. The vehicle seat assembly (eg, 400) includes a seat frame (eg, 402) supporting a foam-free cushion of any of the foregoing techniques.

[0298] A mold such as a porous plate (e.g., 500) is described. The mold (e.g., porous plate 500) includes a solid body defining more than one orifice, the more than one orifice (e.g., 504) having a first group (e.g., 506) of orifices and a second group (e.g., 508) of orifices, the first group (e.g., 506) of orifices being present at a first orifice density and having a first average diameter, the second group (e.g., 508) of orifices being present at a second orifice density and having a second average diameter, wherein the first orifice density is different from the second orifice density and / or the first average diameter is different from the second average diameter.

[0299] In some embodiments, the first pore density is different than the second pore density.

[0300] In some embodiments, the first average diameter is different from the second average diameter.

[0301] In some embodiments, the first pore density does not exceed 11.5 pores per square inch.

[0302] In some embodiments, the first average diameter and the second average diameter differ by at least 0.4.

[0303] In some embodiments, the first pore density and the second pore density differ by at least 3.0 kg / m 3 .

[0304] A system for dispensing a polymer resin is described. The system includes an extruder in which a perforated plate (e.g., 500) of any of the above-described techniques is disposed so that during operation, the extruder extrudes strands of polymer resin through more than one orifice (e.g., 504).

[0305] A method 220 of manufacturing a seat pad is described. The method 220 includes dispensing 222 molten polymer resin through a die (e.g., 500) defining more than one orifice (e.g., 504) to dispense more than one polymer strand into a media interface defined by a first medium and a second medium such that at least a portion of the polymer strands deflect, intertwine, and harden to form a non-foam pad in the second medium.

[0306] The method 220 includes removing 224 the non-foam cushion from the second medium. The method 220 includes drying 226 the non-foam cushion. The more than one apertures include (i) a first group (e.g., 506) of apertures arranged at a first density and defining a first average diameter and (ii) a second group (e.g., 508) of apertures arranged at a second density and defining a second average diameter, the first density being different from the second density and / or the first average diameter being different from the second average diameter, such that the non-foam cushion has a first region having a first hardness and a second region having a second hardness different from the first hardness.

[0307] In some embodiments, more than one orifice (eg, 504) is defined by an interchangeable multi-well plate.

[0308] In some embodiments, more than one aperture (eg, 504) is arranged to form a size gradient and / or a distribution gradient such that the non-foam cushion has a gradient hardness.

[0309] In some embodiments, more than one orifice (e.g., 504) includes a third group of orifices (e.g., 510) such that the non-foam pad has a third region having a third hardness greater than a second hardness, the second hardness being greater than the first hardness, and the second region is disposed between the first region and the third region.

[0310] In some embodiments, more than one orifice (e.g., 504) includes a third group of orifices such that the non-foam pad has a third region having a third hardness different from the second hardness and within 10% of the first hardness, and the second region is disposed between the first region and the third region.

[0311] Although exemplary embodiments are described above, this does not mean that these embodiments describe all possible forms according to the present disclosure. In this regard, the words used in this specification are descriptive rather than restrictive, and it should be understood that multiple changes can be made without departing from the spirit and scope of the present disclosure. In addition, the features of multiple implementation embodiments can be combined to form other embodiments according to the present disclosure.

[0312] Item 1. A method for producing a vehicle interior component, comprising: heating a polymer material to a molten state so that the polymer material becomes a molten polymer; introducing the molten polymer into a mold plate, the mold plate having a first region and a second region, the first region comprising more than one first hole passing therethrough, the second region comprising more than one second hole passing therethrough, the first holes together defining a first open space per unit area in the first region, and the second holes together defining a second open space per unit area in the second region, and wherein the first open space per unit area is greater than the second open space per unit area; and cooling the molten polymer after the molten polymer leaves the mold plate.

[0313] Item 2. The method of claim 1 or any subsequent item, wherein there are more first holes per unit area in the first region than there are second holes per unit area in the second region.

[0314] Item 3. The method of any preceding or subsequent item, wherein the first hole has a diameter that is larger than a diameter of the second hole.

[0315] Item 4. A method according to any one of the preceding or subsequent items, wherein cooling the polymer after it leaves the mold plate produces a liner blank, the method further comprising masking a portion of the mold plate with a template having a predetermined contour portion so that the liner blank has a cross-section defined by the predetermined contour portion.

[0316] Item 5. The method of any preceding or subsequent item, wherein the second region includes a location corresponding to a location of an occupant sensor in the cushion blank.

[0317] Item 6. The method of any preceding or subsequent item, wherein the mold plate includes two first regions, each first region being positioned in a position corresponding to a respective bolster region of the cushion blank.

[0318] Item 7. A method according to any of the preceding or subsequent items, wherein the mold plate includes a third region, the third region includes more than one third hole passing therethrough, the third holes together defining a third open space per unit area in the third region, and wherein the third open space per unit area is less than the second open space per unit area.

[0319] Item 8. A vehicle interior component formed by the method described in any one of the preceding or subsequent items.

[0320] Item 9. A method for producing vehicle interior parts, comprising: heating a polymer material to a molten state so that the polymer material becomes a molten polymer; introducing the molten polymer into a mold plate, the mold plate comprising a first region having an open portion and a closed portion and a second region having an open portion and a closed portion, and wherein a ratio of the open portion of the first region to the first region is greater than a ratio of the open portion of the second region to the second region; and cooling the molten polymer after the molten polymer leaves the mold plate.

[0321] Item 10. A method according to any of the preceding or subsequent items, wherein the first region includes more than one first hole defining the open portion of the first region, and the second region includes more than one second hole defining the open portion of the second region, and wherein the number of the first holes per unit area in the first region is greater than the number of the second holes per unit area in the second region.

[0322] Item 11. A method according to any of the preceding or subsequent items, wherein the first region includes more than one first hole defining the open portion of the first region, and the second region includes more than one second hole defining the open portion of the second region, and wherein the first hole has a diameter larger than the diameter of the second hole.

[0323] Item 12. The method of any preceding or subsequent item, wherein the vehicle interior component comprises a cushion blank having a cross-section, the method further comprising masking a portion of the mold plate with a template having a contour defining the cross-section of the cushion blank.

[0324] Item 13. The method of any preceding or subsequent item, wherein the mold plate includes more than one first region, each first region being positioned in a location corresponding to a respective bolster region of the cushion blank.

[0325] Item 14. The method of any preceding or subsequent item, wherein the second region comprises a location configured to receive an occupant sensor in the cushion blank.

[0326] Item 15. A method according to any of the preceding or subsequent items, wherein the mold plate also includes a third area having an open portion and a closed portion, and wherein the ratio of the open portion of the second area to the second area is greater than the ratio of the open portion of the third area to the third area.

[0327] Item 16. A mold plate equipment that can be used to produce vehicle interior parts, comprising: a plate, the plate including a first area and a second area, the first area including more than one first hole passing therethrough, the second area including more than one second hole passing therethrough, the first holes together defining a first open portion in the first area, and the second holes together defining a second open portion in the second area, and wherein a ratio of the first open portion to the first area is greater than a ratio of the second open portion to the second area.

[0328] Item 17. The die plate arrangement of any preceding or subsequent item, wherein there are more first holes per unit area in the first region than there are second holes per unit area in the second region.

[0329] Item 18. The die plate arrangement of any preceding or subsequent item, wherein the first hole has a diameter that is larger than a diameter of the second hole.

[0330] Item 19. The mold plate equipment according to any of the preceding or subsequent items further includes a template configured to cover at least a portion of the first hole, at least a portion of the second hole, or at least a portion of the first hole and the second hole, the template having a predetermined contour portion defining a cross-section of a portion of the vehicle interior component.

[0331] Item 20. The mold plate arrangement of any preceding or subsequent item, wherein the vehicle interior component is a seat cushion, and the plate includes two of the first regions, each of the first regions being positioned in a position corresponding to a respective bolster region of the seat cushion.

[0332] Item 21. A method of manufacturing a product, comprising: dispensing molten thermoplastic resin through a tool having apertures sized to match the entire perimeter of the product, the tool producing more than one strand through the tool apertures while retaining the more than one strand within the entire perimeter of the product; and bending the strands by obstructing the flow of the more than one strands, the bent strands intersecting into an integral nonwoven body in the shape of the entire perimeter of the product.

[0333] Item 22. The method of any preceding or subsequent item, further comprising cooling more than one strand into a unitary nonwoven product.

[0334] Item 23. The method of any preceding or subsequent item, further comprising: dispensing molten thermoplastic resin from more than one nozzle, the more than one nozzles collectively comprising an area larger than the area of ​​the aperture; and closing a subset of the more than one nozzles outside the area of ​​the aperture.

[0335] Item 24. The method of any preceding or subsequent item, further comprising providing a plate as the tool.

[0336] Item 25. The method of any preceding or subsequent item, further comprising cooling the tool.

[0337] Item 26. The method according to any of the preceding or subsequent items, further comprising providing a casting mold having the pores as the tool.

[0338] Item 27. The method of any preceding or subsequent item, further comprising providing cooling channels through the mold to cool the unitary nonwoven product.

[0339] Item 28. The method of any preceding or subsequent item, further comprising placing the casting mold in a cooling fluid that cools the unitary nonwoven product.

[0340] Item 29. A product manufactured according to the following method, the method comprising: dispensing molten thermoplastic resin through a tool having apertures sized to match the entire perimeter of the product, the tool producing more than one strand through the tool apertures while retaining the more than one strand within the entire perimeter of the product; and bending the strands by blocking the flow of the more than one strands, the bent strands intersecting into an integral nonwoven body in the shape of the entire perimeter of the product.

[0341] Item 30. The product of any preceding or subsequent item, wherein the product further comprises an integral nonwoven liner.

[0342] Item 31. The product of any preceding or subsequent item, wherein the product further comprises a concavely contoured perimeter.

[0343] Item 32. A tool comprising: a tool body having a through hole, the through hole being sized to match the entire perimeter of a pad, the through hole being configured to receive molten thermoplastic resin as more than one allocated strand; and a tool through hole, the tool through hole being configured to retain the more than one allocated strand within the entire perimeter of the pad.

[0344] Item 33. The tool of any preceding or subsequent item, wherein the through-hole is formed into a seat pad, the through-hole being configured to form a unitary nonwoven pad.

[0345] Item 34. The tool of any preceding or subsequent item, wherein the through-holes are formed with a curvature, the through-holes being configured to form a unitary nonwoven mat with a curvature.

[0346] Item 35. The tool of any preceding or subsequent item, wherein the through hole is provided with more than one bend of at least 12 mm radius.

[0347] Item 36. The tool of any preceding or subsequent item, wherein the through hole is formed with a convex perimeter to form a concave surface on the pad.

[0348] Item 37. A system for manufacturing a gasket, comprising: a dispenser of molten thermoplastic resin; and a tool according to any preceding or subsequent item, the tool being oriented relative to the dispenser to receive the molten thermoplastic resin.

[0349] Item 38. The system of any preceding or subsequent item, further comprising a fluid chamber for receiving the molten thermoplastic resin to block the flow of the more than one dispensed strands to cause the strands to flex to intersect into a unitary nonwoven body in the shape of the entire perimeter of the pad.

[0350] Item 39. The system of any preceding or subsequent item, wherein the tool is oriented within the fluid chamber to cool the more than one dispensed strands into a unitary nonwoven mat.

[0351] Item 40. The system of any preceding or subsequent item, wherein a cooling channel is formed through the tool to cool the more than one dispensed strands into the unitary nonwoven mat.

[0352] Item 41. A method comprising: distributing a molten thermoplastic resin into more than one strand and at least one film; and blocking the flow of the distributed more than one strand, wherein the blocking causes the more than one strand to expand by causing at least a subset of the more than one strand to cross and combine with each other and with the at least one film into a unitary body.

[0353] Item 42. The method of any preceding or subsequent item, further comprising cooling the more than one strands and the at least one film as a unitary product.

[0354] Item 43. The method of any preceding or subsequent item, further comprising: cooling the more than one strands and the at least one membrane with a fluid, wherein flow of the more than one strands is blocked by the fluid.

[0355] Item 44. The method of any preceding or subsequent item, further comprising cooling the more than one strands in the fluid chamber.

[0356] Item 45. The method of any preceding or subsequent item, further comprising dispensing the at least one film on an outer surface of the monolithic body.

[0357] Item 46. The method of any preceding or subsequent item, further comprising distributing the at least one film between at least two subsets of the more than one strands.

[0358] Item 47. The method of any preceding or subsequent item, further comprising forming pores through the at least one membrane.

[0359] Item 48. The method of any preceding or subsequent item, wherein dispensing further comprises: dispensing the more than one strands through more than one aperture in a tool; and dispensing the at least one film through at least one slit in the tool.

[0360] Item 49. The method according to any of the preceding or subsequent items further includes: removing the tool from the extruder; installing a second tool to the extruder; distributing the molten thermoplastic resin into a second one or more strands and a second film through the second tool; and blocking the flow of the distributed second one or more strands, by causing at least a subset of the second one or more strands to cross each other and the second film to form a second integral body different from the first integral body, and the blocking causes the second one or more strands to expand.

[0361] Item 50. The method of any preceding or subsequent item, further comprising assembling a seat with a cushion formed by the method.

[0362] Item 51. A product formed by the method according to any preceding or subsequent item.

[0363] Item 52. A product formed by a method comprising: distributing a molten thermoplastic resin into more than one strand and at least one film; and blocking the flow of the distributed more than one strand, wherein the blocking causes the more than one strand to expand by intersecting at least a subset of the more than one strands with each other and with the at least one film as a unitary body.

[0364] Item 53. The product formed by the method according to any of the preceding or subsequent items, further comprising: forming the at least one film on the outer surface of the monolithic body.

[0365] Item 54. The product formed by the method of any preceding or subsequent item, further comprising: forming the at least one membrane as an impermeable membrane between at least two subsets of the more than one strands.

[0366] Item 55. The product formed by the method of any preceding or subsequent item, further comprising: forming pores through the at least one membrane.

[0367] Item 56. A seat assembly manufactured by a method comprising: assembling a seat with a cushion formed by a method according to any preceding or subsequent item.

[0368] Item 57. The seat assembly manufactured by the method of any preceding or subsequent item, further comprising: attaching at least one of a seat trim, an actuator, and / or a heat transfer layer to the at least one film.

[0369] Item 58. A product comprising: an extended network of more than one interconnected thermoplastic strands; and at least one thermoplastic film integrally bonded to at least a subset of the more than one strands into a unitary body.

[0370] Item 59. The product of any preceding or subsequent item, wherein the at least one film is oriented on an exterior surface of the monolithic body.

[0371] Item 60. The product of any preceding or subsequent item, wherein the at least one membrane is impermeable.

[0372] Item 61. The product of any preceding or subsequent item, wherein the at least one film is oriented between at least two subsets of the more than one strands.

[0373] Item 62. A product according to any preceding or subsequent item, wherein the pores extend through the at least one membrane.

[0374] Item 63. A seat assembly comprising a product according to any preceding or subsequent item as a seat pad.

[0375] Item 64. The seat assembly of any preceding or subsequent item, further comprising at least one of a seat trim, an actuator, and / or a heat transfer layer attached to the at least one membrane.

[0376] Item 65. A tool comprising a body having more than one apertures formed therethrough and at least one slit formed therethrough to distribute molten thermoplastic resin through the more than one apertures and the at least one slit.

[0377] Item 66. A system comprising: an extruder of a molten thermoplastic resin; and a tool according to any of the preceding or subsequent items, the tool being mounted to the extruder to distribute the molten thermoplastic resin into more than one strand and at least one film through the tool.

[0378] Item 67. A method for producing a vehicle interior component, comprising: heating a polymer material to a molten state so that the polymer material becomes a molten polymer; introducing the molten polymer into a mold plate having more than one hole arranged to pass therethrough so that the molten polymer moves through the holes and forms more than one molten polymer filament; surrounding the molten polymer filaments with a heating device, the heating device being operable to apply heat to the molten polymer filaments; and introducing the molten polymer filaments into a bath to cool the molten polymer filaments to form a consolidated filament structure.

[0379] Item 68. The method of any preceding or subsequent item, wherein the heating equipment comprises a rectangular heating structure to surround the molten polymer filaments as they exit the die plate.

[0380] Item 69. The method of any preceding or subsequent item, wherein the mold plate comprises more than one side, and the heating equipment is attached to each side of the mold plate.

[0381] Item 70. The method of any preceding or subsequent item, wherein the heating equipment is configured to control the ambient temperature surrounding the molten polymer filaments to a temperature of 60°C-140°C.

[0382] Item 71. The method of any preceding or subsequent item, wherein the heating equipment is positioned at least 100 mm-150 mm from the molten polymer filaments.

[0383] Item 72. A method according to any of the preceding or subsequent items, wherein the molten polymer filaments include an outer portion disposed toward an outer edge of the mold plate and an inner portion disposed inward from the outer portion, and the heating equipment is configured to heat the outer portion so that bonding between the molten polymer filaments of the outer portion is greater than bonding between the molten polymer filaments of the inner portion.

[0384] Item 73. A method according to any of the preceding or subsequent items, wherein the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, and the method further includes introducing a second molten polymer comprising a second material into the mold plate so that the second molten polymer moves through the holes in the mold plate and forms more than one second molten polymer filament.

[0385] Item 74. A method according to any of the preceding or subsequent items, wherein the first molten polymer is introduced into the mold plate toward the outer edge of the mold plate, and the second molten polymer is introduced into the mold plate inward from the first molten polymer so that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0386] Item 75. A vehicle interior component formed by the method according to any preceding or subsequent item.

[0387] Item 76. A method for producing a vehicle interior component, comprising: heating a first polymer material to a molten state to produce a first molten polymer; extruding the first molten polymer to form more than one first molten polymer filament; heating the entire periphery of the first molten polymer filament; and cooling the first molten polymer filament in a fluid bath to produce a consolidated filament structure.

[0388] Item 77. The method of any preceding or subsequent item, wherein the first molten polymer comprises a first material, and the method further comprises extruding a second molten polymer comprising a second material to form more than one second molten polymer filament.

[0389] Item 78. The method of any preceding or subsequent item, wherein the first molten polymer and the second molten polymer are extruded such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0390] Item 79. The method of any preceding or subsequent item, wherein heating the entire perimeter of the first molten polymer filament comprises heating the first molten polymer filament on four sides of the first molten polymer filament.

[0391] Item 80. The method of any preceding or subsequent item, wherein heating the entire circumference of the first molten polymer filament comprises heating the first molten polymer filament to a temperature of 60°C to 140°C.

[0392] Item 81. The method of any preceding or subsequent item, wherein the entire perimeter of the first molten polymer filaments is heated such that bonding between the first molten polymer filaments is greater than bonding between the second molten polymer filaments.

[0393] Item 82. A vehicle interior component formed by the method according to any preceding or subsequent item.

[0394] Item 83. A method for producing a vehicle interior component, comprising: heating a polymer material to produce a molten polymer; forming more than one molten polymer filament from the molten polymer by extruding the molten polymer through a die plate; heating the entire periphery of the molten polymer filament with a heating device; and cooling the molten polymer filaments in a fluid bath to form a consolidated filament structure.

[0395] Item 84. The method of any preceding or subsequent item, wherein the heating equipment is attached to the mold plate.

[0396] Item 85. A method according to any of the preceding or subsequent items, wherein the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, and the method further includes introducing a second molten polymer comprising a second material into the mold plate so that the second molten polymer moves through the mold plate and forms more than one second molten polymer filament.

[0397] Item 86. A method according to any of the preceding or subsequent items, wherein the first molten polymer is introduced into the mold plate toward the outer edge of the mold plate, and the second molten polymer is introduced into the mold plate inward from the first molten polymer so that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0398] Item 87. A vehicle seat cushion component, comprising: a plastic mesh base, the plastic mesh base including one or more first three-dimensional filament loops, the first one or more three-dimensional filament loops being composed of a first thermoplastic polymer, the plastic mesh base having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; a first bolster, the first bolster being attached to the plastic mesh base at the first edge, a first foamed bolster including one or more second three-dimensional filament loops, the second one or more three-dimensional filament loops being composed of a second thermoplastic polymer different from the first thermoplastic polymer; and a second bolster, the second bolster being attached to the plastic mesh base at the second edge.

[0399] Item 88. The vehicle seat cushion component of any preceding or subsequent item, wherein the second bolster comprises a third more than one three-dimensional filament loops comprised of a second thermoplastic polymer.

[0400] Item 89. The vehicle seat cushion component of any preceding or subsequent item, wherein the second bolster comprises a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

[0401] Item 90. The vehicle seat cushion component of any preceding or subsequent item, wherein the second bolster comprises a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different from the first thermoplastic polymer and the second thermoplastic polymer.

[0402] Item 91. The vehicle seat cushion component of any preceding or subsequent item, wherein the second bolster comprises a third more than one three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

[0403] Item 92. The vehicle seat cushion component of any preceding or subsequent item, further comprising a third bolster comprising a fourth more than one three-dimensional filament loop, the fourth more than one three-dimensional filament loop being composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0404] Item 93. The vehicle seat cushion component of any preceding or subsequent item, wherein the more than one three-dimensional filament loops include more than one fused connection in which two loops are attached to each other.

[0405] Item 94. The vehicle seat cushion component of any preceding or subsequent item, wherein at least a subset of the more than one three-dimensional filament loops are not parallel or aligned with each other.

[0406] Item 95. The vehicle seat cushion component of any preceding or subsequent item, wherein the loops in the more than one three-dimensional filament loops are randomly oriented.

[0407] Item 96. The vehicle seat cushion component of any preceding or subsequent item, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0408] Item 97. A vehicle seat cushion component according to any preceding or subsequent item, 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.

[0409] Item 98. The vehicle seat pad component of any preceding or subsequent item, wherein the thermoplastic polymer comprises a first linear low density polyethylene.

[0410] Item 99. The vehicle seat cushion component of any preceding or subsequent item, wherein the thermoplastic polymer comprises a second linear low density polyethylene different from the first linear low density polyethylene.

[0411] Item 100. A seat assembly comprising: a frame; and a cushion according to any preceding or subsequent item, the cushion being supported by the frame.

[0412] Item 101. A tool comprising: a mold defining a series of pores arranged to extrude material for a twisted mesh material component for a cushion according to any of the preceding or subsequent items, the series of pores arranged to define an outer periphery of the component to define the plastic mesh base, the first bolster and the second bolster.

[0413] Item 102. The tool of any preceding or subsequent item, wherein the series of apertures is further arranged such that the outer perimeter defines the bolster.

[0414] Item 103. A method comprising: extruding a first thermoplastic polymer to form a plastic mesh base comprising a first one or more three-dimensional filament loops, the plastic mesh base having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; and extruding a second thermoplastic polymer to form a first bolster attached to the plastic mesh base at the first edge, a first foamed bolster comprising a second one or more three-dimensional filament loops, the second thermoplastic polymer being different from the first thermoplastic polymer; and extruding material to form a second bolster attached to the plastic mesh base at the second edge.

[0415] Item 104. The method of any preceding or subsequent item, wherein the second bolster comprises a third more than one three-dimensional filament loop, the third more than one three-dimensional filament loop being comprised of the second thermoplastic polymer.

[0416] Item 105. The method of any preceding or subsequent item, wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

[0417] Item 106. A method according to any of the preceding or subsequent items, wherein the second bolster comprises a third or more three-dimensional filament loops, wherein the third or more three-dimensional filament loops are composed of a third thermoplastic polymer different from the first thermoplastic polymer and the second thermoplastic polymer.

[0418] Item 107. The method of any preceding or subsequent item, wherein the second bolster comprises a third or more three-dimensional filament loops comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

[0419] Item 108. The method of any preceding or subsequent item further includes a third bolster comprising a fourth or more three-dimensional filament loops comprised of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0420] Item 109. A foam-free seat pad comprising: more than one interwoven polymer strands, the more than one interwoven polymer strands having a first group of interwoven polymer strands having a first hardness and a second group of interwoven polymer strands having a second hardness different from the first hardness, wherein the first group of interwoven polymer strands and the second group of interwoven polymer strands are connected.

[0421] Item 110. The foam-free seat pad of any preceding or subsequent item, wherein the first set of interwoven polymeric strands has a first average diameter and the second set of interwoven polymeric strands has a second average diameter different than the first average diameter.

[0422] Item 111. The foam-free seat pad of any preceding or subsequent item, wherein the first set of interwoven polymeric strands defines a first packing density and the second set of interwoven polymeric strands has a second packing density different from the first density.

[0423] Item 112. The foam-free seat pad of any preceding or subsequent item, wherein the first hardness is less than the second hardness and the first hardness is no greater than 5 kPa.

[0424] Item 113. The foam-free seat pad of any preceding or subsequent item, wherein the second hardness is at least 5 kPa.

[0425] Item 114. A foam-free seat pad according to any of the preceding or subsequent items, further comprising a third group of interwoven polymer strands having a third hardness from the more than one interwoven polymer strands, the second group of interwoven polymer strands being arranged between the first group of interwoven polymer strands and the third group of interwoven polymer strands such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

[0426] Item 115. The foam-free seat pad of any preceding or subsequent item, wherein the more than one interwoven polymer strands form a hardness gradient from a first region of the pad to a second region of the pad.

[0427] Item 116. A vehicle seat assembly comprising a seat frame supporting a foam-free cushion according to any preceding or subsequent item.

[0428] Item 117. A porous plate comprising: a solid body defining more than one orifice, the more than one orifice having a first group of orifices and a second group of orifices, the first group of orifices existing at a first orifice density and having a first average diameter, the second group of orifices existing at a second orifice density and having a second average diameter, wherein the first orifice density is different from the second orifice density and / or the first average diameter is different from the second average diameter.

[0429] Item 118. The multiwell plate of any preceding or subsequent item, wherein the first pore density is different than the second pore density.

[0430] Item 119. The porous plate of any preceding or subsequent item, wherein the first average diameter is different from the second average diameter.

[0431] Item 120. The porous plate of any preceding or subsequent item, wherein the first pore density is no more than 11.5 pores per square inch.

[0432] Item 121. The porous plate of any preceding or subsequent item, wherein the first average diameter and the second average diameter differ by at least 0.4.

[0433] Item 122. A porous plate according to any preceding or subsequent item, wherein the first pore density and the second pore density differ by at least 3.0 kg / m 3 .

[0434] Item 123. A system for dispensing a polymer resin, comprising an extruder in which a porous plate according to any of the preceding or subsequent items is disposed, so that during operation, the extruder extrudes strands of polymer resin through the more than one orifice during operation.

[0435] Item 124. A method for manufacturing a seat cushion, comprising: dispensing a molten polymer resin through a mold defining more than one orifice to dispense more than one polymer strand into a media interface defined by a first medium and a second medium, so that at least a portion of the polymer strands are deflected, intertwined and hardened to form a non-foam cushion in the second medium; removing the non-foam cushion from the second medium; and drying the non-foam cushion, wherein the more than one orifice includes (i) a first group of orifices arranged at a first density and defining a first average diameter and (ii) a second group of orifices arranged at a second density and defining a second average diameter, the first density being different from the second density and / or the first average diameter being different from the second average diameter, so that the non-foam cushion has a first region having a first hardness and a second region having a second hardness different from the first hardness.

[0436] Item 125. The method of any preceding or subsequent item, wherein the more than one orifice is defined by an interchangeable porous plate.

[0437] Item 126. The method of any preceding or subsequent item, wherein the more than one apertures are arranged to form a size gradient and / or a distribution gradient such that the non-foam pad has a gradient hardness.

[0438] Item 127. A method according to any of the preceding or subsequent items, wherein the more than one orifice includes a third group of orifices, so that the non-foam pad has a third area, the third area has a third hardness greater than the second hardness, the second hardness is greater than the first hardness, and the second area is arranged between the first area and the third area.

[0439] Item 128. A method according to any of the preceding or subsequent items, wherein the more than one orifice includes a third group of orifices, so that the non-foam pad has a third region, the third region has a third hardness different from the second hardness and within 10% of the first hardness, and the second region is disposed between the first region and the third region.

[0440] Item 129. A cushion, such as for a vehicle seat, comprising a (e.g., nonwoven) web body. The web body comprises more than one interconnected polymer filaments, (i) comprising a first subset of polymer filaments and a second subset of polymer filaments that is different (e.g., different composition, hardness, density, shape, size, and / or thickness) from the first subset of polymer filaments; and / or (ii) at least a portion of the interconnected polymer filaments is bonded to a polymer film.

[0441] Item 130. A pad as described in any preceding or subsequent item, wherein the first subset and the second subset are interconnected.

[0442] Item 131. A pad according to any of the preceding or subsequent items, wherein (a) the first subset has a first hardness and the second subset has a second hardness different from the first hardness, (b) the first subset has a first density and the second subset has a second density different from the first density, (c) the first subset has a first filament size (e.g., chain length / molecular weight / average diameter) and the second subset has a second filament size (e.g., chain length / molecular weight / average diameter), and / or (d) the first subset is formed from a first polymer material (e.g., polyethylene) and the second subset is formed from a second polymer material different from the first polymer material (e.g., polypropylene, polystyrene, polycarbonate, or polyvinyl chloride).

[0443] Item 132. A pad as described in any preceding or subsequent item, wherein the first dimension is a first average (eg, larger / thicker) diameter and the second dimension is a second average (eg, smaller / thinner) diameter.

[0444] Item 133. The pad of any preceding or subsequent item, wherein the mesh body has a contoured profile.

[0445] Item 134. The pad of any preceding or subsequent item, wherein the hardness is bulk hardness.

[0446] Item 135. The pad of any preceding or subsequent item, wherein the pad is foam-free.

[0447] Item 136. The liner of any preceding or subsequent item, wherein the portion of the interconnected polymer filaments is integrally bonded to a polymer film.

[0448] Item 137. The liner of any preceding or subsequent item, wherein the interconnected polymer filaments and the polymer film are made of the same polymer material.

[0449] Item 138. The pad of any preceding or subsequent item, wherein the film forms a skin along the web body.

[0450] Item 139. The pad of any preceding or subsequent item, wherein the mesh body is nonwoven.

[0451] Item 140. The pad of any preceding or subsequent item, wherein the mesh body comprises a base portion and a further bolster portion.

[0452] Item 141. A cushion as recited in any preceding or subsequent item, wherein the first subset forms the base portion and the second subset forms the additional bolster portion.

[0453] Item 142. A pad as described in any preceding or subsequent item, wherein the base portion defines a first profile and the additional portion defines a second profile different from the first profile.

[0454] Item 143. The cushion of any preceding or subsequent item, wherein the additional bolster portion comprises a first bolster.

[0455] Item 144. The cushion of any preceding or subsequent item, wherein the first bolster is attached to the base portion at a first edge of the base portion.

[0456] Item 145. The pad of any preceding or subsequent item, wherein the first bolster comprises a second subset of polymer filaments.

[0457] Item 146. A pad as described in any of the preceding or subsequent items, wherein a first subset of polymer filaments comprises a first polymer material and a second subset of polymer filaments comprises a second polymer material different from the first polymer material (e.g., different composition, shape, size).

[0458] Item 147. The cushion of any preceding or subsequent item, wherein the additional bolster portion comprises a second bolster.

[0459] Item 148. The cushion of any preceding or subsequent item, wherein the second bolster is attached to the base portion at a second edge of the base portion.

[0460] Item 149. The cushion of any preceding or subsequent item, wherein the second bolster is opposite the first bolster.

[0461] Item 150. A pad according to any of the preceding or subsequent items, wherein the second bolster comprises a third subset of polymer filaments from the more than one interconnected polymer filaments, and the third subset of polymer filaments is different from the first subset of polymer filaments and / or the second subset of polymer filaments (e.g., different composition, shape, size).

[0462] Item 151. The liner of any preceding or subsequent item, wherein the third subset of polymer filaments comprises a third polymer material different from the first polymer material and / or the second polymer material.

[0463] Item 152. The cushion of any preceding or subsequent item, wherein the additional bolster portion comprises a third bolster.

[0464] Item 153. The cushion of any preceding or subsequent item, wherein the third bolster is attached to the base portion at a third edge of the base portion.

[0465] Item 154. The pad of any preceding or subsequent item, wherein the third edge is a rear edge of the base portion.

[0466] Item 155. A pad according to any of the preceding or subsequent items, wherein the third bolster comprises a fourth subset of polymer filaments, the fourth subset of polymer filaments being different from the first subset of polymer filaments, the second subset of polymer filaments, and / or the third subset of polymer filaments.

[0467] Item 156. The liner of any preceding or subsequent item, wherein a fourth subset of the polymer filaments comprises a fourth polymer material different from the first polymer material, the second polymer material, and / or the third polymer material.

[0468] Item 157. The cushion of any preceding or subsequent item, wherein the additional bolster portion includes a fourth bolster.

[0469] Item 158. The cushion of any preceding or subsequent item, wherein the fourth bolster is attached to the base portion at a fourth edge.

[0470] Item 159. The cushion of any preceding or subsequent item, wherein the fourth bolster is opposite the third bolster.

[0471] Item 160. The pad of any preceding or subsequent item, wherein the fourth edge is a front edge of the base portion.

[0472] Item 161. A pad according to any of the preceding or subsequent items, wherein the fourth bolster comprises a fifth subset of polymer filaments, the fifth subset of polymer filaments being different from the first subset of polymer filaments, the second subset of polymer filaments, the third subset of polymer filaments and / or the fourth subset of polymer filaments.

[0473] Item 162. A liner according to any of the preceding or subsequent items, wherein the fifth subset of the polymer filaments comprises a fifth polymer material different from the first polymer material, the second polymer material, the third polymer material and / or the fourth polymer material.

[0474] Item 163. The pad of any preceding or subsequent item, wherein the more than one interconnected polymer filaments comprise a thermoplastic polymer.

[0475] Item 164. A pad as described in any preceding or subsequent item, wherein the density is a bulk density.

[0476] Item 165. A pad as described in any preceding or subsequent item, wherein the first hardness is no greater than 5 kPa.

[0477] Item 166. A pad as described in any of the preceding or subsequent items, wherein the first hardness is less than the second hardness.

[0478] Item 167. A pad according to any preceding or subsequent item, wherein the second hardness is at least 5 kPa.

[0479] Item 168. A pad as described in any of the preceding or subsequent items, wherein the more than one interconnected polymer filaments include a third subset of polymer filaments, the third subset of polymer filaments being different from the first subset of polymer filaments and different from the second subset of polymer filaments.

[0480] Item 169. A pad as described in any of the preceding or subsequent items, wherein the third subset has a hardness that is different from the hardness of the first subset and the second subset.

[0481] Item 170. The pad of any preceding or subsequent item, wherein the second subset is disposed between the first subset and the third subset.

[0482] Item 171. A pad as described in any of the preceding or subsequent items, wherein the first subset has a first hardness and the second subset has a second hardness, such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

[0483] Item 172. The pad of any preceding or subsequent item, wherein the more than one interconnected polymer filaments have a hardness gradient from a first region to a second region.

[0484] Item 173. The liner of any preceding or subsequent item, wherein the polymer film is arranged such that the polymer film forms an outer surface (eg, skin) of a mesh body.

[0485] Item 174. The liner of any preceding or subsequent item, wherein the polymer film is impermeable (eg, impermeable to air or liquid).

[0486] Item 175. The liner of any preceding or subsequent item, wherein the polymer film is disposed between the first subset of polymer filaments and the second subset of polymer filaments.

[0487] Item 176. The liner of any preceding or subsequent item, wherein the polymer film defines pores.

[0488] Item 177. The pad of any preceding or subsequent item, wherein the more than one interconnected polymer filaments include more than one fused connection in which at least two filaments are bonded to each other.

[0489] Item 178. The liner of any preceding or subsequent item, wherein at least a portion of the polymer filaments are non-parallel or non-aligned.

[0490] Item 179. The pad of any preceding or subsequent item, wherein the polymer filaments of the more than one interconnected polymer filaments are randomly oriented.

[0491] Item 180. The liner of any preceding or subsequent item, wherein the more than one interconnected polymer filaments comprise a polymer selected from the group consisting of polyolefins, polyethylenes, polystyrenes, polyesters, polyurethanes, and polyamides.

[0492] Item 181. The liner of any preceding or subsequent item, wherein the polyethylene is a low density polyethylene.

[0493] Item 182. The liner of any preceding or subsequent item, wherein the polyethylene is linear.

[0494] Item 183. The liner of any preceding or subsequent item, wherein the more than one interconnected polymer filaments comprise an additional polyethylene different from the first polyethylene.

[0495] Item 184. The cushion of any preceding or subsequent item, wherein the cushion is a seat cushion.

[0496] Item 185. A seat assembly comprising a frame supporting a cushion according to any preceding or subsequent item.

[0497] Item 186. A seat assembly as described in any preceding or subsequent item, wherein the seat assembly is a vehicle seat assembly.

[0498] Item 187. The seat assembly of any preceding or subsequent item, further comprising a seat trim, an actuator, and / or a heat transfer layer attached to the polymer film.

[0499] Item 188. A vehicle comprising a floor and a seat assembly according to any preceding or subsequent item mounted to the floor.

[0500] Item 189. A mold tool (e.g., a mold / perforated plate and / or a funnel) comprising a solid body (e.g., a metal body) defining a first section (e.g., a section for forming a central seat cushion portion) and a second segment (e.g., a segment for forming a bolster), the first segment defining a first one or more orifices (e.g., a first subset of nozzles / holes) such that the first segment defines a first open space (e.g., a collective open area of ​​the holes) and a first enclosed portion, the second segment defining one or more orifices (e.g., a second subset of nozzles / holes) such that the second segment defines a second open space (e.g., a collective open area of ​​the holes) and a second enclosed portion, wherein (i) the first open space and the first enclosed portion are different from the second open space and the second enclosed portion (i.e., different orifice density / shape / size / different perimeter), (ii) the orifices define a shape of a final product having a first profile and a second profile different from the first profile, (iii) the one or more orifices include elongated orifices to define a polymer film, and / or (iv) the first one or more orifices (e.g., the first subset) are different (e.g., in density, shape, size, number, etc.) from the one or more orifices (e.g., the second subset).

[0501] Item 190. A mold tool according to any of the preceding or subsequent items, wherein the first section (e.g., forming a central pad portion) has an aperture density (e.g., apertures per unit area) that is different from the aperture density of the second section (e.g., the bolster).

[0502] Item 191. A mold tool according to any of the preceding or subsequent items, wherein the size (e.g., average diameter) of the first more than one orifices (e.g., a first subset) is different from the size (e.g., average diameter) of the one or more orifices (e.g., a second subset).

[0503] Item 192. A mold tool according to any of the preceding or subsequent items, wherein the first more than one orifices (e.g., a first subset) of the first section have an average diameter that is different from the average diameter of the one or more orifices (e.g., a second subset) of the second section.

[0504] Item 193. A mold tool according to any of the preceding or subsequent items, wherein the one or more orifices (e.g., a second subset) form at least one slit (e.g., a hole forming a polymer film) through the solid body (e.g., a metal body).

[0505] Item 194. The mold tool of any preceding or subsequent item, wherein the orifice of the mold tool is arranged to dispense molten thermoplastic resin.

[0506] Item 195. The mold tool of any preceding or subsequent item, wherein the one or more apertures are arranged to define an outer perimeter of a cushion having a first bolster and a second bolster.

[0507] Item 196. The mold tool of any preceding or subsequent item, wherein the one or more orifices is a second more than one orifice.

[0508] Item 197. A mold tool according to any of the preceding or subsequent items, wherein the first section defines a first area, the first open space defines a first open area, the second section defines a second area, and the second open space defines a second open area, wherein the ratio of the first open area to the first area is greater than the ratio of the second open area to the second area.

[0509] Item 198. A mold tool according to any of the preceding or subsequent items, wherein the one or more apertures comprise a through hole sized to match the entire perimeter of the gasket (e.g., to provide a skin along an outer edge).

[0510] Item 199. The mold tool of any preceding or subsequent item, wherein the through-hole is configured to receive molten thermoplastic resin and distribute the molten thermoplastic resin into more than one molten filament.

[0511] Item 200. The mold tool of any preceding or subsequent item, wherein the through-hole is configured to hold the more than one molten filaments together in a final shape of a final product.

[0512] Item 201. The mold tool of any preceding or subsequent item, wherein the first orifice density does not exceed 8 orifices per square inch.

[0513] Item 202. The mold tool of any preceding or subsequent item, wherein the second aperture density is at least 9 apertures per square inch.

[0514] Item 203. The mold tool of any preceding or subsequent item, wherein the first average diameter and the second average diameter differ by at least 0.4 mm.

[0515] Item 204. The mold tool of any preceding or subsequent item, wherein there are more orifices per unit area in the first section than in the second section.

[0516] Item 205. A mold tool according to any of the preceding or subsequent items, further comprising a template configured to cover the more than one orifices and / or at least a portion of the one or more orifices (e.g., it may overlay / cover a portion of the mold to define a cross-sectional shape of the final product).

[0517] Item 206. The mold tool of any preceding or subsequent item, wherein the template has a predetermined contour portion defining a cross-section of a portion of a vehicle interior component.

[0518] Item 207. The mold tool of any preceding or subsequent item, wherein the template has a predetermined contour portion defining a cross-section of a portion of the cushion.

[0519] Item 208. The mold tool of any preceding or subsequent item, wherein the first section is positioned in a location corresponding to a corresponding bolster portion of a seat cushion.

[0520] Item 209. The mold tool of any preceding or subsequent item, wherein the through hole is formed into a seat pad.

[0521] Item 210. The mold tool of any preceding or subsequent item, wherein the through holes are configured to form a unitary nonwoven mat.

[0522] Item 211. The mold tool of any preceding or subsequent item, wherein the through-holes are shaped to have a curvature to form a unitary nonwoven mat having a curvature.

[0523] Item 212. A mold tool as described in any preceding or subsequent item, wherein the through hole is provided with more than one bend of at least 12 mm radius.

[0524] Item 213. The mold tool of any preceding or subsequent item, wherein the through hole is formed with a convex perimeter to form a concave surface of the liner.

[0525] Item 214. A dispensing system comprising a dispenser (e.g., an extruder) on which is disposed a mold tool according to any of the preceding or subsequent items, so that during operation, the dispenser dispenses molten thermoplastic resin through an orifice of the mold tool.

[0526] Item 215. The dispensing system of any preceding or subsequent item, wherein the dispenser is an extruder for extruding the molten thermoplastic resin through the orifice of the die tool to form molten thermoplastic filaments.

[0527] Item 216. A dispensing system according to any of the preceding or subsequent items, further comprising a fluid chamber (e.g., a cooling bath) for receiving the molten thermoplastic filaments and blocking the flow of the molten thermoplastic filaments, which causes the filaments to flex so that they cross and / or bond together to form a unitary nonwoven body in the shape of the entire periphery of the pad.

[0528] Item 217. The dispensing system of any preceding or subsequent item, wherein the die tool is aligned with the fluid chamber to cool the molten thermoplastic filaments into a unitary nonwoven mat.

[0529] Item 218. The dispensing system of any preceding or subsequent item, wherein the die tool defines cooling channels formed therethrough to cool molten thermoplastic filaments into a unitary nonwoven mat.

[0530] Item 219. A vehicle interior component comprising more than one interconnected polymer filaments dispensed through a mold tool according to any preceding or subsequent item.

[0531] Item 220. A pad comprising more than one interconnected polymer filaments dispensed through a die tool according to any preceding or subsequent item.

[0532] Item 221. A method such as for producing a vehicle seat cushion, comprising dispensing (e.g., extruding) a molten polymer resin through a mold assembly (e.g., a mold plate, a template and / or a funnel), the mold assembly having a first region and a second region, the first region defining a first one or more pores (e.g., a first subset) for dispensing the molten polymer filaments, the second region defining one or more additional pores (e.g., a second subset) for dispensing additional molten polymer components (e.g., additional filaments and / or films) different from the molten polymer filaments, wherein the first region defines a first ratio of a first blocked area (e.g., a solid portion of the mold plate) to a first open area (e.g., a collection of pores), the first ratio being different from a second ratio of a second blocked area to a second open area of ​​the second region; and cooling the molten polymer filaments and the additional molten polymer components to form a (e.g., nonwoven) web body comprising interconnected polymer filaments and having a first portion different from a second portion.

[0533] Item 222. The method of any preceding or subsequent item, wherein the mesh body is a non-foam pad.

[0534] Item 223. The method of any preceding or subsequent item, wherein the mesh body is a vehicle interior component.

[0535] Item 224. The method of any preceding or subsequent item, wherein the additional molten polymer member is an additional polymer filament having a different shape, size, density and / or composition.

[0536] Item 225. The method of any preceding or subsequent item, wherein the molten polymer material is extruded through the die assembly.

[0537] Item 226. The method of any preceding or subsequent item, wherein the first one or more apertures or the one or more additional apertures define a perimeter in the shape of a final product (eg, a vehicle seat pad).

[0538] Item 227. The method of any preceding or subsequent item, wherein the final product is a seat pad.

[0539] Item 228. The method of any preceding or subsequent item, wherein the final product is a vehicle interior component.

[0540] Item 229. A method according to any of the preceding or subsequent items, wherein the first more than one pores (e.g., a first subset of pores) define a first profile that is different from a second profile defined by the one or more additional pores (e.g., a second subset of pores).

[0541] Item 230. The method of any preceding or subsequent item, wherein the additional molten polymer member is a polymer film.

[0542] Item 231. The method of any preceding or subsequent item, wherein the polymer film is connected to the interconnected polymer filaments.

[0543] Item 232. The method of any preceding or subsequent item, wherein the polymer film is bonded to the interconnected polymer filaments.

[0544] Item 233. A method according to any of the preceding or subsequent items, wherein the molten polymer filaments are distributed into a medium interface (e.g., an air / water interface) defined by a first medium (e.g., air) and a second medium (e.g., water) so that at least a subset of the molten polymer filaments deflect and / or bend (e.g., change direction) so that at least a subset of the molten polymer filaments cross, interweave, entangle and / or bond while hardening, such as from cooling water, to form a (e.g., nonwoven) web body in the second medium (e.g., water).

[0545] Item 234. The method of any preceding or subsequent item, further comprising removing the (eg, nonwoven) mesh body from the second medium (eg, water) and drying the (eg, nonwoven) mesh body.

[0546] Item 235. A method according to any of the preceding or subsequent items, wherein the first medium is a gas (e.g., air) and the second medium is a liquid (e.g., water).

[0547] Item 236. A method according to any preceding or subsequent item, wherein the first medium is air and the second medium is water.

[0548] Item 237. A method according to any of the preceding or subsequent items, wherein the more than one pores (e.g., a first subset) are arranged at a first pore density and the one or more additional pores (e.g., a second subset) are arranged at a second pore density different from the first pore density.

[0549] Item 238. The method of any preceding or subsequent item, wherein the more than one pores define a first average diameter and the one or more additional pores define a second average diameter different from the first average diameter.

[0550] Item 239. A method according to any of the preceding or subsequent items, wherein the first portion of the (e.g., nonwoven) mesh body has a first hardness and the second portion of the (e.g., nonwoven) mesh body has a second hardness different from the first hardness.

[0551] Item 240. A method according to any of the preceding or subsequent items, wherein a first thermoplastic polymer is dispensed through the orifices of the first region so that the first portion is a plastic mesh base of interconnected polymer filaments, and a second thermoplastic polymer is dispensed through one or more orifices of the second region so that the second portion is a first plastic mesh pillow of interconnected polymer filaments attached to the plastic mesh base, the second thermoplastic polymer being different from the first thermoplastic polymer.

[0552] Item 241. The method of any of the preceding or subsequent items further includes dispensing (e.g., extruding) the first thermoplastic polymer, the second thermoplastic polymer, or a third thermoplastic polymer (e.g., different from the first material and / or the second material) through a third region of the mold assembly such that a third portion of the mesh body is a second plastic mesh pillow.

[0553] Item 242. A method according to any of the preceding or subsequent items, wherein the plastic mesh base includes a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face, and the first plastic mesh bolster is attached to the plastic mesh base at the first edge.

[0554] Item 243. The method of any preceding or subsequent item, wherein the second plastic mesh bolster is attached to the plastic mesh base at the second edge.

[0555] Item 244. A method according to any of the preceding or subsequent items, wherein the first more than one pores (e.g., a first subset) in the first region of the mold plate define a first open space per unit area, and the one or more additional pores in the second region define a second open space per unit area in the second region, such that the first open space per unit area is greater than the second open space per unit area.

[0556] Item 245. The method according to any of the preceding or subsequent items further includes heating the polymer material to a molten state so that when the polymer material is received by and dispensed through the mold assembly, the polymer material forms the molten polymer filaments and / or the additional molten polymer components.

[0557] Item 246. The method of any preceding or subsequent item, further comprising surrounding the molten polymer filaments with a heating device operable to apply heat to the molten polymer filaments.

[0558] Item 247. The method of any preceding or subsequent item, further comprising introducing the molten polymer filaments and / or the additional molten polymer members into a cooling bath to form the web body of interconnected polymer filaments.

[0559] Item 248. A method according to any preceding or subsequent item, wherein the second medium (eg, water) is disposed in a cooling (eg, water) bath.

[0560] Item 249. A method according to any of the preceding or subsequent items, wherein the mold assembly includes a mold plate.

[0561] Item 250. A method according to any of the preceding or subsequent items, wherein the mold assembly includes a template.

[0562] Item 251. The method of any preceding or subsequent item, wherein cooling occurs after the molten polymer filaments exit the die plate.

[0563] Item 252. A method according to any of the preceding or subsequent items, wherein the one or more additional apertures include apertures sized to match the entire perimeter of the product, and the mold assembly retains the molten polymer filaments within the entire perimeter of the product.

[0564] Item 253. A method according to any of the preceding or subsequent items, wherein there are more pores per unit area in the first region than there are pores per unit area in the second region.

[0565] Item 254. A method according to any of the preceding or subsequent items, wherein the first more than one pores comprise a diameter that is larger than a diameter of the one or more additional pores.

[0566] Item 255. The method of any preceding or subsequent item further comprises masking (e.g., covering) a portion of a mold plate with a template comprising a predetermined contour such that the (nonwoven) web body has a cross-section defined by the predetermined contour.

[0567] Item 256. A method as described in any of the preceding or subsequent items, wherein the second area includes a location corresponding to a location of an occupant sensor in the mesh body.

[0568] Item 257. A method as recited in any preceding or subsequent item, wherein the second region corresponds to a corresponding bolster region of a cushion.

[0569] Item 258. A method according to any of the preceding or subsequent items, wherein the mold assembly includes a third region defining a second more than one pore, the third region defining a third ratio of a third blocked area to a third open area, the third ratio being different from the first ratio and / or the second ratio.

[0570] Item 259. A method according to any of the preceding or subsequent items, wherein the third open area per unit area is smaller than the first area per unit area and / or the second area per unit area.

[0571] Item 260. The method of any preceding or subsequent item, further comprising heating the entire circumference of the molten polymer filament.

[0572] Item 261. The method of any preceding or subsequent item, further comprising replacing the mold assembly or a portion thereof with a second mold assembly or a portion thereof (interchangeability).

[0573] Item 262. A method according to any preceding or subsequent item, wherein the mold assembly or a portion thereof comprises an interchangeable mold plate or template.

[0574] Item 263. A method according to any of the preceding or subsequent items, wherein the more than one pores form a size gradient or a distribution gradient along the mold assembly such that the mesh body includes a hardness gradient.

[0575] Item 264. A method according to any of the preceding or subsequent items, wherein the third region of the mold assembly is configured to provide a third portion of the mesh body, the third portion of the mesh body having a third hardness greater than a second hardness of the second portion of the mesh body, the second hardness greater than a first hardness of the first portion of the (e.g., nonwoven) mesh body.

[0576] Item 265. A method according to any preceding or subsequent item, wherein the second portion is disposed between the first portion and the third portion.

[0577] Item 266. A method according to any of the preceding or subsequent items, wherein the third portion has a hardness different from the second hardness and within 10% of the first hardness.

[0578] Item 267. A method according to any preceding or subsequent item, wherein the additional molten polymer member (eg, film) is dispensed on an outer surface of the mesh body.

[0579] Item 268. The method of any preceding or subsequent item, further comprising dispensing the film on an outer surface of the mesh body.

[0580] Item 269. A method according to any preceding or subsequent item, wherein the additional molten polymer member (eg, film) is distributed between at least two subsets of the interconnected polymer filaments.

[0581] Item 270. The method of any preceding or subsequent item, further comprising distributing a film between at least two subsets of the interconnected polymer filaments.

[0582] Item 271. The method of any preceding or subsequent item, further comprising forming pores through the membrane.

[0583] Item 272. A method according to any preceding or subsequent item, wherein the one or more additional pores (eg, the second subset) comprise slits to distribute the membrane as an additional polymer component.

[0584] Item 273. The method of any preceding or subsequent item, further comprising removing the dispensing assembly or a portion thereof and installing a second dispensing assembly or a portion thereof.

[0585] Item 274. The method of any preceding or subsequent item, further comprising dispensing different web bodies via the second dispensing assembly or a portion thereof.

[0586] Item 275. The method of any preceding or subsequent item, further comprising assembling a seat with the (eg, nonwoven) mesh body.

[0587] Item 276. A method according to any preceding or subsequent item, wherein the membrane is an impermeable membrane.

[0588] Item 277. The method of any preceding or subsequent item, further comprising attaching at least one of a seat trim, an actuator, and / or a heat transfer layer to the membrane.

[0589] Item 278. The method of any preceding or subsequent item, wherein the heating equipment comprises a rectangular heating structure to surround the molten polymer filaments as they exit the die assembly.

[0590] Item 279. The method of any preceding or subsequent item, wherein a heating device is attached to a side of the mold assembly.

[0591] Item 280. The method of any preceding or subsequent item, wherein heating equipment is attached to each side of the mold assembly.

[0592] Item 281. A method according to any preceding or subsequent item, wherein the mold assembly is rectangular.

[0593] Item 282. The method of any preceding or subsequent item, wherein the heating equipment controls the temperature of the air surrounding the molten polymer filaments to a temperature of 60°C to 140°C.

[0594] Item 283. The method of any preceding or subsequent item, wherein the heating equipment is positioned at least 100 mm to 150 mm from the molten polymer filaments.

[0595] Item 284. A method according to any of the preceding or subsequent items, wherein the molten polymer filaments include an outer portion disposed toward an outer edge of the mold assembly and an inner portion disposed inward from the outer portion, and the heating equipment is configured to heat the outer portion so that bonding between the molten polymer filaments of the outer portion is greater than bonding between the molten polymer filaments of the inner portion.

[0596] Item 285. A method according to any of the preceding or subsequent items, wherein a first polymer material is dispensed through the first region of the mold assembly and a second polymer material is dispensed through the second region of the mold assembly, the second polymer material (e.g., polyethylene) being different from the first polymer material (e.g., polypropylene, polystyrene, polycarbonate and / or polyvinyl chloride).

[0597] Item 286. A method according to any of the preceding or subsequent items, wherein a second polymer material is introduced into the mold assembly toward the outer edge of the mold assembly and the first polymer material is introduced into the mold assembly inward from the second polymer material so that the additional molten polymer member at least partially surrounds the first polymer filament.

[0598] Item 287. The method of any preceding or subsequent item, further comprising dispensing a third polymer material through the mold assembly, the third polymer material being different from the first polymer material and / or the second polymer material.

[0599] Item 288. A method according to any of the preceding or subsequent items, wherein the third polymer material is different from the first polymer material and the second polymer material, and the first polymer material and the second polymer material are different from each other.

[0600] Item 289. A method according to any preceding or subsequent item, wherein the first more than one pores collectively have an area that is larger than an area of ​​the one or more additional pores.

[0601] Item 290. A method according to any preceding or subsequent item, wherein the first one or more apertures form more than one nozzle, and the method further comprises closing the more than one nozzle or a subset thereof outside the one or more additional apertures.

[0602] Item 291. The method of any preceding or subsequent item, further comprising cooling the mold assembly.

[0603] Item 292. The method of any preceding or subsequent item, further comprising providing a casting mold having the one or more additional pores as the mold component.

[0604] Item 293. A method according to any preceding or subsequent item, wherein the casting mold includes cooling channels therethrough to cool the mesh body.

[0605] Item 294. The method according to any of the preceding or subsequent items further includes placing the casting mold in a cooling fluid so that the cooling fluid cools the mesh body.

[0606] Item 295. A method according to any of the preceding or subsequent items, wherein the mesh body also includes a perimeter with a concave profile.

[0607] Item 296. A product such as a vehicle seat liner formed by the method according to any preceding or subsequent item.

[0608] Item 297. A vehicle interior component formed by a method according to any preceding or subsequent item.

[0609] Item 298. A system such as for producing a non-foam seat cushion for a vehicle, the system comprising a forming component (e.g., a mold, a template, a funnel), the forming component comprising a mold plate having a first region and a second region, the first region having more than one pore, the second region having one or more additional pores different from the more than one pore; and an extruder that extrude one or more polymer materials through the forming component to form a mesh cushion body.

[0610] Item 299. A system according to any of the preceding or subsequent items, further comprising a die plate that blocks a portion of a pore, a funnel that directs molten polymer filaments extruded through the die plate into a monolithic body and / or a cooling bath, a heating device that heats the molten polymer filaments, and / or a conveyor assembly that transports the monolithic body through the cooling bath.

[0611] Item 300. A system according to any of the preceding or subsequent items, wherein (i) the first region of the mold plate defines a first enclosed portion and a first open space, and the second region defines a second enclosed portion and a second open space, such that the first enclosed portion is different from the second enclosed portion and / or the first open space is different from the second open space, (ii) the first region defines a perimeter in the shape of a final product, (iii) the one or more additional pores include slits for dispensing a polymer film, (iv) a first pore density of the first region is different from a second pore density of the second region, and / or (v) a size of the more than one pore is different from a size of the one or more additional pores.

[0612] Item 301. A system according to any of the preceding items, wherein the first region defines a first profile and the second region defines a second profile different from the first profile.

Claims

1. A method for producing a vehicle interior component, comprising: heating the polymer material to a molten state so that the polymer material becomes a molten polymer; introducing the molten polymer into a mold plate having a first region and a second region, the first region comprising more than one first hole therethrough, the second region comprising more than one second hole therethrough, the first holes together defining a first open space per unit area in the first region, and the second holes together defining a second open space per unit area in the second region, and wherein the first open space per unit area is greater than the second open space per unit area; and The molten polymer is cooled after it leaves the die plate. 2 . The method of claim 1 , wherein the first holes per unit area in the first region are more than the second holes per unit area in the second region. The method according to claim 1 , wherein the first hole has a diameter larger than a diameter of the second hole.

4. A method according to any one of the preceding claims, wherein cooling the polymer after it leaves the mold plate produces a liner blank, the method further comprising masking a portion of the mold plate with a template having a predetermined contour portion so that the liner blank has a cross-section defined by the predetermined contour portion. 5 . The method of claim 4 , wherein the second region includes a location corresponding to a location of an occupant sensor in the cushion blank.

6. The method of claim 4 or 5, wherein the mold plate comprises two of the first regions, each first region being positioned in a position corresponding to a respective bolster region of the cushion blank.

7. The method of claim 6 wherein the mold plate includes a third region comprising more than one third hole therethrough, the third holes together defining a third open space per unit area in the third region, and wherein the third open space per unit area is less than the second open space per unit area.

8. A vehicle interior component formed by a method according to any one of the preceding claims.

9. A method for producing a vehicle interior component, comprising: heating the polymer material to a molten state so that the polymer material becomes a molten polymer; introducing the molten polymer into a mold plate, the mold plate comprising a first region having an open portion and a closed portion and a second region having an open portion and a closed portion, and wherein a ratio of the open portion of the first region to the first region is greater than a ratio of the open portion of the second region to the second region; and The molten polymer is cooled after it leaves the die plate.

10. The method of claim 9, wherein the first region comprises more than one first hole defining the open portion of the first region, and the second region comprises more than one second hole defining the open portion of the second region, and wherein there are more first holes per unit area in the first region than there are second holes per unit area in the second region.

11. A method according to claim 9 or 10, wherein the first area includes more than one first hole defining the open portion of the first area, and the second area includes more than one second hole defining the open portion of the second area, and wherein the first hole has a diameter larger than the diameter of the second hole.

12. The method of any one of claims 9-11, wherein the vehicle interior component comprises a cushion blank having a cross-section, the method further comprising masking a portion of the mold plate with a template having a contour defining the cross-section of the cushion blank.

13. The method of claim 12, wherein the mold plate includes more than one first region, each first region being positioned in a location corresponding to a respective bolster region of the cushion blank.

14. The method of claim 12 or 13, wherein the second region comprises a location configured to receive an occupant sensor in the cushion blank.

15. The method according to any one of claims 9-14, wherein the mold plate further comprises a third region having an open portion and a closed portion, and wherein a ratio of the open portion of the second region to the second region is greater than a ratio of the open portion of the third region to the third region.

16. A mold plate equipment capable of being used for producing vehicle interior parts, comprising: A plate comprising a first region and a second region, the first region comprising more than one first hole therethrough, the second region comprising more than one second hole therethrough, the first holes together defining a first open portion in the first region, and the second holes together defining a second open portion in the second region, and wherein a ratio of the first open portion to the first region is greater than a ratio of the second open portion to the second region.

17. The die plate arrangement of claim 16, wherein there are more first holes per unit area in the first region than there are second holes per unit area in the second region.

18. A die plate arrangement according to claim 16 or 17, wherein the first hole has a diameter which is larger than the diameter of the second hole.

19. The mold plate equipment according to any one of claims 16-18, further comprising a template configured to cover at least a portion of the first hole, at least a portion of the second hole, or at least a portion of the first hole and the second hole, the template having a predetermined contour portion defining a cross-section of a portion of the vehicle interior component.

20. The mold plate arrangement of any one of claims 16-19, wherein the vehicle interior component is a seat pad, and the plate comprises two of the first regions, each of the first regions being positioned in a position corresponding to a respective bolster region of the seat pad.

21. A method of manufacturing a product, comprising: dispensing molten thermoplastic resin through a tool having an aperture sized to match the entire perimeter of a product, the tool producing more than one strand through the tool aperture while retaining the more than one strand within the entire perimeter of the product; and By blocking the flow of the more than one strand, the strands are buckled, the buckled strands intersecting into a unitary nonwoven body in the shape of the entire perimeter of the product.

22. The method of claim 21 further comprising cooling the more than one strands into a unitary nonwoven product.

23. The method according to claim 21, further comprising: dispensing the molten thermoplastic resin from more than one nozzle, the more than one nozzles collectively comprising an area larger than an area of ​​the aperture; as well as A subset of the more than one nozzles outside of a region of the aperture is closed.

24. The method of claim 21, further comprising providing a plate as the tool.

25. The method of claim 21 further comprising cooling the tool.

26. The method of claim 21, further comprising providing a casting mold having the pores as the tool.

27. The method of claim 26, further comprising providing cooling passages through the mold to cool the unitary nonwoven product.

28. The method of claim 27, further comprising placing the mold in a cooling fluid, the cooling fluid cooling the unitary nonwoven product.

29. A product manufactured according to the following method, the method comprising: dispensing molten thermoplastic resin through a tool having an aperture sized to match the entire perimeter of a product, the tool producing more than one strand through the tool aperture while retaining the more than one strand within the entire perimeter of the product; and By blocking the flow of the more than one strand, the strands are buckled, the buckled strands intersecting into a unitary nonwoven body in the shape of the entire perimeter of the product.

30. The product of claim 29, wherein the product further comprises an integral nonwoven liner.

31. The product of claim 29, wherein the product further comprises a concavely contoured perimeter.

32. A tool comprising: a tool body having a through hole sized to match the entire perimeter of the pad, the through hole configured to receive molten thermoplastic resin as more than one dispensed strand; as well as A tool through-hole is configured to retain the more than one dispensed strands within the entire perimeter of the pad.

33. The tool of claim 32, wherein the through hole is formed into a seat pad, the through hole being configured to form a unitary nonwoven pad.

34. The tool of claim 32, wherein the through-holes are formed with a curvature, the through-holes being configured to form a unitary nonwoven pad with a curvature.

35. The tool of claim 32, wherein the through hole is provided with more than one bend having a radius of at least 12 mm.

36. The tool of claim 32, wherein the through hole is formed with a convex perimeter to form a concave surface on the pad.

37. A system for manufacturing a liner, comprising: a dispenser for molten thermoplastic resin; as well as The tool of claim 32, said tool being oriented relative to said dispenser to receive said molten thermoplastic resin.

38. The system of claim 37 further comprising a fluid chamber for receiving the molten thermoplastic resin to block the flow of the more than one dispensed strands to cause the strands to flex to intersect into a unitary nonwoven body in the shape of the entire perimeter of the pad.

39. The system of claim 38, wherein the tool is oriented within the fluid chamber to cool the more than one dispensed strands into a unitary nonwoven mat.

40. The system of claim 39, wherein cooling channels are formed through the tool to cool the more than one dispensed strands into the unitary nonwoven mat.

41. A method comprising: distributing a molten thermoplastic resin into more than one strand and at least one film; as well as The flow of the dispensed more than one strand is blocked, the blockage causing the more than one strand to expand by interleaving and bonding at least a subset of the more than one strands to each other and to the at least one membrane as a unitary body.

42. The method of claim 41 further comprising cooling the more than one strands and the at least one film as a unitary product.

43. The method of claim 42, further comprising: The more than one strands and the at least one membrane are cooled with a fluid, wherein flow of the more than one strands is blocked by the fluid.

44. The method of claim 43, further comprising cooling the more than one strands in the fluid chamber.

45. The method of any of the preceding claims, further comprising dispensing the at least one film on an outer surface of the monolithic body.

46. ​​The method of any of the preceding claims, further comprising distributing the at least one membrane between at least two subsets of the more than one strands.

47. The method of any preceding claim, further comprising forming pores through the at least one membrane.

48. The method of any preceding claim, wherein allocating further comprises: dispensing the more than one strands through more than one aperture in the tool; as well as The at least one film is dispensed through at least one slit in the tool.

49. The method of claim 48, further comprising: removing the tool from the extruder; installing a second tool to the extruder; distributing the molten thermoplastic resin into a second plurality of strands and a second film through the second tool; as well as The flow of the dispensed second more than one strands is blocked, the blocking causing the second more than one strands to expand by interleaving at least a subset of the second more than one strands with each other and the second membrane into a second unitary body different from the first unitary body.

50. A method according to any preceding claim, further comprising assembling a seat with a cushion formed by the method.

51. A product formed by the method of any preceding claim.

52. A product formed by the following method, the method comprising: distributing a molten thermoplastic resin into more than one strand and at least one film; as well as The flow of the distributed more than one strand is blocked, the blockage causing the more than one strand to expand by intersecting at least a subset of the more than one strands with each other and the at least one membrane as a unitary body.

53. The product formed by the method of claim 52, further comprising: The at least one film is formed on an outer surface of the monolithic body.

54. A product formed by the method of claim 52 or 53, further comprising: The at least one membrane is formed as an impermeable membrane between at least two subsets of the more than one strands.

55. A product formed by the method according to any one of claims 52-54, further comprising: Apertures are formed through the at least one membrane.

56. A seat assembly manufactured by the following method, the method comprising: Assemble a seat with a cushion formed by the method of any one of claims 52-55.

57. The seat assembly manufactured by the method of claim 56, further comprising: At least one of a seat trim, an actuator, and / or a heat transfer layer is attached to the at least one film.

58. A product comprising: an extended web of more than one interconnected thermoplastic strand; as well as At least one thermoplastic film is integrally bonded to at least a subset of the more than one strands into a unitary body.

59. A product as defined in claim 58 wherein the at least one film is oriented on an exterior surface of the unitary body.

60. The product of claim 58 or 59, wherein the at least one membrane is impermeable.

61. The product of any one of claims 58-60, wherein the at least one film is oriented between at least two subsets of the more than one strands.

62. The product of any one of claims 58-61, wherein pores extend through the at least one membrane.

63. A seat assembly comprising a product according to any one of claims 58 to 62 as a seat pad.

64. The seat assembly of claim 63, further comprising at least one of a seat trim, an actuator, and / or a heat transfer layer attached to the at least one membrane.

65. A tool comprising a body having more than one apertures formed therethrough and at least one slit formed therethrough to dispense molten thermoplastic resin through the more than one apertures and the at least one slit.

66. A system comprising: an extruder for molten thermoplastic resin; as well as The tool of claim 65, mounted to the extruder to distribute the molten thermoplastic resin through the tool into more than one strand and at least one film.

67. A method for producing a vehicle interior component, comprising: heating the polymer material to a molten state so that the polymer material becomes a molten polymer; introducing the molten polymer into a die plate having more than one aperture disposed therethrough such that the molten polymer moves through the apertures and forms more than one molten polymer filament; surrounding the molten polymer filaments with a heating device operable to apply heat to the molten polymer filaments; as well as The molten polymer filaments are introduced into a bath to cool the molten polymer filaments to form a consolidated filament structure.

68. The method of claim 67, wherein the heating apparatus comprises a rectangular heating structure to surround the molten polymer filaments as they exit the die plate.

69. A method according to claim 67 or 68, wherein the mould plate comprises more than one side and the heating equipment is attached to each side of the mould plate.

70. The method of any preceding claim, wherein the heating equipment is configured to control the ambient temperature surrounding the molten polymer filaments to a temperature of 60°C - 140°C.

71. The method of any preceding claim, wherein the heating equipment is positioned at least 100 mm-150 mm from the molten polymer filaments.

72. A method according to any of the preceding claims, wherein the molten polymer filaments include an outer portion disposed toward an outer edge of the mold plate and an inner portion disposed inward from the outer portion, and the heating equipment is configured to heat the outer portion so that bonding between the molten polymer filaments of the outer portion is greater than bonding between the molten polymer filaments of the inner portion.

73. A method according to any of the preceding claims, wherein the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, and the method further comprises introducing a second molten polymer comprising a second material into the mold plate so that the second molten polymer moves through the holes in the mold plate and forms more than one second molten polymer filament.

74. A method according to claim 73, wherein the first molten polymer is introduced into the mold plate toward the outer edge of the mold plate, and the second molten polymer is introduced into the mold plate inward from the first molten polymer so that the first molten polymer filaments at least partially surround the second molten polymer filaments.

75. A vehicle interior component formed by a method according to any preceding claim.

76. A method for producing a vehicle interior component, comprising: heating a first polymer material to a molten state to produce a first molten polymer; extruding the first molten polymer to form more than one first molten polymer filament; heating the entire circumference of the first molten polymer filament; as well as The first molten polymer filaments are cooled in a fluid bath to produce a consolidated filament structure.

77. The method of claim 76, wherein the first molten polymer comprises a first material, and the method further comprises extruding a second molten polymer comprising a second material to form more than one second molten polymer filament.

78. The method of claim 77, wherein the first molten polymer and the second molten polymer are extruded such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

79. The method of any one of claims 76-78, wherein heating the entire perimeter of the first molten polymer filament comprises heating the first molten polymer filament on four sides of the first molten polymer filament.

80. The method of any one of claims 76-79, wherein heating the entire circumference of the first molten polymer filaments comprises heating the first molten polymer filaments to a temperature of 60°C to 140°C.

81. The method of any one of claims 76-80, wherein the entire perimeter of the first molten polymer filaments is heated such that bonding between the first molten polymer filaments is greater than bonding between the second molten polymer filaments.

82. A vehicle interior component formed by the method of any one of claims 76-81.

83. A method for producing a vehicle interior component, comprising: heating the polymer material to produce a molten polymer; forming more than one molten polymer filament from the molten polymer by extruding the molten polymer through a die plate; heating the entire circumference of the molten polymer filaments with a heating device; and The molten polymer filaments are cooled in a fluid bath to form a consolidated filament structure.

84. The method of claim 83, wherein the heating equipment is attached to the mold plate.

85. A method according to claim 83 or 84, wherein the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, and the method further comprises introducing a second molten polymer comprising a second material into the mold plate so that the second molten polymer moves through the mold plate and forms more than one second molten polymer filament.

86. A method according to claim 85, wherein the first molten polymer is introduced into the mold plate toward the outer edge of the mold plate, and the second molten polymer is introduced into the mold plate inward from the first molten polymer so that the first molten polymer filaments at least partially surround the second molten polymer filaments.

87. A vehicle seat cushion component, comprising: a plastic mesh base, the plastic mesh base comprising a first one or more three-dimensional filament loops, the first one or more three-dimensional filament loops being composed of a first thermoplastic polymer, the plastic mesh base having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; a first bolster attached to the plastic mesh base at the first edge, the first foamed bolster comprising a second one or more three-dimensional filament loops, the second one or more three-dimensional filament loops being composed of a second thermoplastic polymer different from the first thermoplastic polymer; as well as A second bolster is attached to the plastic mesh base at the second edge.

88. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of the second thermoplastic polymer.

89. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

90. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer and the second thermoplastic polymer.

91. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of a third thermoplastic polymer different than the first thermoplastic polymer.

92. The vehicle seat cushion component of claims 87-91 further comprising a third bolster comprising a fourth plurality of three-dimensional filament loops comprised of a fourth thermoplastic polymer different than the first thermoplastic polymer.

93. The vehicle seat pad component of claims 87-92 wherein the more than one three-dimensional filament loops include more than one fused connection where two loops are attached to one another.

94. The vehicle seat cushion component of any one of claims 87 to 93, wherein at least a subset of the more than one three-dimensional filament loops are not parallel or aligned with each other.

95. The vehicle seat cushion component of any one of claims 87 to 94, wherein the loops in the more than one three-dimensional filament loops are randomly oriented.

96. The vehicle seat cushion component of any one of claims 87 to 95, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

97. The vehicle seat cushion component of any one of claims 87 to 96, 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.

98. The vehicle seat cushion component of any one of claims 87 to 97, wherein the thermoplastic polymer comprises a first linear low density polyethylene.

99. The vehicle seat cushion component of any one of claims 87 to 97, wherein the thermoplastic polymer comprises a second linear low density polyethylene different from the first linear low density polyethylene.

100. A seat assembly comprising: frame; as well as A pad according to any one of claims 87-99, wherein the pad is supported by the frame.

101. A tool comprising: A die defining a series of pores arranged to extrude material for a twisted mesh material component for a cushion according to any one of claims 87-99, the series of pores arranged to define an outer periphery of the component to define the plastic mesh base, the first bolster and the second bolster.

102. The tool of claim 101 wherein the series of apertures is further arranged such that the outer perimeter defines the bolster.

103. A method comprising: extruding a first thermoplastic polymer to form a plastic mesh base including a first one or more three-dimensional filament loops, the plastic mesh base having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; and extruding a second thermoplastic polymer to form a first bolster attached to the plastic mesh base at the first edge, the first foamed bolster comprising a second more than one three-dimensional filament loop, the second thermoplastic polymer being different from the first thermoplastic polymer; as well as Material is extruded to form a second bolster attached to the plastic mesh base at the second edge.

104. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of the second thermoplastic polymer.

105. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

106. The method of claim 103, wherein the second bolster comprises a third more than one three-dimensional filament loop, wherein the third more than one three-dimensional filament loop is composed of a third thermoplastic polymer different from the first thermoplastic polymer and the second thermoplastic polymer.

107. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

108. The method of claims 103 to 107 further includes a third bolster, wherein the third bolster includes more than one fourth three-dimensional filament loops, and the more than one fourth three-dimensional filament loops are composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

109. A foam-free seat pad comprising: More than one interwoven polymeric strands having a first set of interwoven polymeric strands having a first stiffness and a second set of interwoven polymeric strands having a second stiffness different from the first stiffness, wherein the first set of interwoven polymeric strands and the second set of interwoven polymeric strands are connected.

110. The foam-free seat pad of claim 109 wherein the first set of interwoven polymeric strands have a first average diameter and the second set of interwoven polymeric strands have a second average diameter different than the first average diameter.

111. The foam-free seat pad of any of the preceding claims, wherein the first set of interwoven polymeric strands defines a first packing density and the second set of interwoven polymeric strands has a second packing density different than the first density.

112. The foam-free seat pad of any of the preceding claims, wherein the first hardness is less than the second hardness, and the first hardness is no greater than 5 kPa.

113. The foam-free seat pad of any of the preceding claims, wherein the second hardness is at least 5 kPa.

114. A foam-free seat pad according to any of the preceding claims, further comprising a third group of interwoven polymer strands having a third hardness from the more than one interwoven polymer strands, the second group of interwoven polymer strands being arranged between the first group of interwoven polymer strands and the third group of interwoven polymer strands, such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

115. The foam-free seat pad of any of the preceding claims, wherein the more than one interwoven polymer strands form a gradient of hardness from a first region of the pad to a second region of the pad.

116. A vehicle seat assembly comprising a seat frame supporting a foam-free cushion according to any one of the preceding claims.

117. A multi-well plate comprising: A solid body defining more than one orifice, the more than one orifice having a first group of orifices and a second group of orifices, the first group of orifices existing at a first orifice density and having a first average diameter, the second group of orifices existing at a second orifice density and having a second average diameter, wherein the first orifice density is different from the second orifice density and / or the first average diameter is different from the second average diameter.

118. A porous plate according to claim 117, wherein the first hole density is different from the second hole density.

119. A porous plate according to claim 117 or 118, wherein the first average diameter is different from the second average diameter.

120. A porous plate according to claims 117, 118 or 119, wherein the first hole density does not exceed 11.5 holes / square inch.

121. A porous plate according to any one of claims 117-120, wherein the first average diameter and the second average diameter differ by at least 0.

4.

122. A porous plate according to any one of claims 117-121, wherein the first pore density and the second pore density differ by at least 3.0 kg / m 3 .

123. A system for dispensing a polymer resin, comprising an extruder in which a porous plate according to any one of claims 117-122 is arranged, so that during operation, the extruder extrudes strands of the polymer resin through the more than one orifice during operation.

124. A method of manufacturing a seat cushion, comprising: dispensing molten polymer resin through a die defining more than one orifice to dispense more than one polymer strand into a media interface defined by a first medium and a second medium such that at least a portion of the polymer strands are deflected, intertwined, and hardened to form a non-foam cushion in the second medium; removing the non-foam liner from the second medium; as well as drying the non-foam pad, wherein the more than one orifice comprises (i) a first group of orifices arranged at a first density and defining a first average diameter and (ii) a second group of orifices arranged at a second density and defining a second average diameter, the first density being different from the second density and / or the first average diameter being different from the second average diameter, such that the non-foam pad has a first region having a first hardness and a second region having a second hardness being different from the first hardness.

125. The method of claim 124, wherein the more than one orifice is defined by an interchangeable porous plate.

126. The method of claim 124 or 125, wherein the more than one orifices are arranged to form a size gradient and / or a distribution gradient so that the non-foam pad has a gradient hardness.

127. A method according to claim 124, 125 or 126, wherein the more than one orifice includes a third group of orifices, so that the non-foam pad has a third area, the third area has a third hardness greater than the second hardness, the second hardness is greater than the first hardness, and the second area is arranged between the first area and the third area.

128. A method according to any one of the preceding claims 124-127, wherein the more than one orifice includes a third group of orifices, so that the non-foam pad has a third region, the third region has a third hardness different from the second hardness and within 10% of the first hardness, and the second region is arranged between the first region and the third region.

129. A pad comprising: A mesh body comprising more than one interconnected polymer filaments, wherein (i) the more than one interconnected polymer filaments comprise a first subset of polymer filaments and a second subset of polymer filaments different from the first subset of polymer filaments; and / or (ii) at least a portion of the interconnected polymer filaments are bonded to a polymer film.

130. A pad according to any one of claims 129 or 131-188, wherein the first subset and the second subset are interconnected.

131. A pad according to any one of claims 129-130 or 132-188, wherein (a) the first subset has a first hardness and the second subset has a second hardness different from the first hardness, (b) the first subset has a first density and the second subset has a second density different from the first density, (c) the first subset has a first filament size and the second subset has a second filament size, and / or (d) the first subset is formed of a first polymer material and the second subset is formed of a second polymer material different from the first polymer material.

132. A pad according to any one of claims 129-131 or 133-188, wherein the first dimension is a first average diameter and the second dimension is a second average diameter.

133. A pad according to any one of claims 129-132 or 134-188, wherein the mesh body has a contoured profile.

134. A pad according to any one of claims 129-133 or 135-188, wherein the hardness is a bulk hardness.

135. A pad according to any one of claims 129-134 or 136-188, wherein the pad is foam-free.

136. A liner according to any one of claims 129-135 or 137-188, wherein the portion of the interconnected polymer filaments is integrally bonded to a polymer film.

137. A pad according to any one of claims 129-136 or 138-188, wherein the interconnected polymer filaments and the polymer film are made of the same polymer material.

138. A pad according to any one of claims 129-137 or 139-188, wherein the film forms a skin along the mesh body.

139. A pad according to any one of claims 129-138 or 140-188, wherein the mesh body is nonwoven.

140. A pad according to any one of claims 129-139 or 141-188, wherein the mesh body includes a base portion and an additional bolster portion.

141. A pad according to any one of claims 129-140 or 142-188, wherein the first subset forms the base portion and the second subset forms the additional bolster portion.

142. A pad according to claim 140 or claim 141, wherein the base portion defines a first profile and the further portion defines a second profile different from the first profile.

143. A cushion according to any one of claims 140-142, wherein the additional bolster portion includes a first bolster.

144. The pad of claim 143, wherein the first bolster is attached to the base portion at a first edge of the base portion.

145. A pad according to any of claims 143-144, wherein the first bolster comprises a second subset of the polymer filaments.

146. The liner of claim 145, wherein a first subset of the polymer filaments comprises a first polymer material and a second subset of the polymer filaments comprises a second polymer material different from the first polymer material.

147. A cushion according to any one of claims 143-146, wherein the additional bolster portion includes a second bolster.

148. The pad of claim 147, wherein the second bolster is attached to the base portion at a second edge of the base portion.

149. The cushion of any one of claims 147-148, wherein the second bolster is opposite to the first bolster.

150. A pad according to any one of claims 146, wherein the second bolster comprises a third subset of polymer filaments from the more than one interconnected polymer filaments, and the third subset of polymer filaments is different from the first subset of polymer filaments and / or the second subset of polymer filaments.

151. A pad according to claim 150, wherein the third subset of polymer filaments comprises a third polymer material different from the first polymer material and / or the second polymer material.

152. A cushion according to any one of claims 147-151, wherein the additional bolster portion includes a third bolster.

153. A pad according to claim 152, wherein the third bolster is attached to the base portion at a third edge of the base portion.

154. A pad according to claim 153, wherein the third edge is a rear edge of the base portion.

155. A pad according to any one of claims 152-154, wherein the third bolster comprises a fourth subset of polymer filaments, the fourth subset of polymer filaments being different from the first subset of polymer filaments, the second subset of polymer filaments and / or the third subset of polymer filaments.

156. A pad according to claim 155, wherein a fourth subset of the polymer filaments comprises a fourth polymer material different from the first polymer material, the second polymer material and / or the third polymer material.

157. A pad according to any one of claims 152-156, wherein the additional bolster portion includes a fourth bolster.

158. The pad of claim 157, wherein the fourth bolster is attached to the base portion at a fourth edge.

159. The cushion of any one of claims 157-155, wherein the fourth bolster is opposite the third bolster.

160. A pad according to any one of claims 158-159, wherein the fourth edge is a front edge of the base portion.

161. A pad according to any one of claims 157-160, wherein the fourth bolster comprises a fifth subset of polymer filaments, the fifth subset of polymer filaments being different from the first subset of polymer filaments, the second subset of polymer filaments, the third subset of polymer filaments and / or the fourth subset of polymer filaments.

162. A liner according to claim 161, wherein a fifth subset of the polymer filaments comprises a fifth polymer material different from the first polymer material, the second polymer material, the third polymer material and / or the fourth polymer material.

163. A pad according to any of claims 129-162 or 164-188, wherein the more than one interconnected polymer filaments comprise a thermoplastic polymer.

164. A pad according to any one of claims 131-163 or 165-188, wherein the density is a bulk density.

165. A pad according to any one of claims 129-164 or 166-188, wherein the first hardness is no greater than 5 kPa.

166. A pad according to any one of claims 129-165 or 167-188, wherein the first hardness is less than the second hardness.

167. A pad according to any one of claims 129-166 or 168-188, wherein the second hardness is at least 5 kPa.

168. A pad according to any one of claims 129-167 or 169-188, wherein the more than one interconnected polymer filaments include a third subset of polymer filaments, and the third subset of polymer filaments is different from the first subset of polymer filaments and different from the second subset of polymer filaments.

169. A pad according to claim 168, wherein the third subset has a hardness different from the hardness of the first subset and the second subset.

170. A pad according to any one of claims 168-169, wherein the second subset is disposed between the first subset and the third subset.

171. A pad according to any one of claims 168-170, wherein the first subset has a first hardness and the second subset has a second hardness, such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

172. A pad according to any of claims 129-171 or 173-188, wherein the more than one interconnected polymer filaments have a hardness gradient from a first region to a second region.

173. A pad according to any one of claims 129-172 or 174-188, wherein the polymer film is arranged so that the polymer film forms an outer surface of the mesh body.

174. A liner according to any one of claims 129-173 or 175-188, wherein the polymer film is impermeable.

175. A liner according to any one of claims 129-174 or 176-188, wherein the polymer film is arranged between a first subset of polymer filaments and a second subset of polymer filaments.

176. A liner according to any one of claims 129-175 or 176-188, wherein the polymer film defines pores.

177. A pad according to any one of claims 129-176 or 178-188, wherein the more than one interconnected polymer filaments include more than one fused connection in which at least two filaments are bonded to each other.

178. A pad according to any one of claims 129-177 or 179-188, wherein at least a portion of the polymer filaments are non-parallel or non-aligned.

179. A pad according to any one of claims 129-178 or 180-188, wherein the polymer filaments in the more than one interconnected polymer filaments are randomly oriented.

180. A pad according to any one of claims 129-179 or 181-188, wherein the more than one interconnected polymer filaments include a polymer selected from the group consisting of polyolefins, polyethylenes, polystyrenes, polyesters, polyurethanes, and polyamides.

181. The pad of claim 180 wherein the polyethylene is a low density polyethylene.

182. The liner of any one of claims 180-181 wherein the polyethylene is linear.

183. A liner according to any one of claims 180-182, wherein the more than one interconnected polymer filaments include an additional polyethylene different from the first polyethylene.

184. A cushion according to any one of claims 129-183, wherein the cushion is a seat cushion.

185. A seat assembly comprising a frame supporting a cushion according to any one of claims 129-184.

186. The seat assembly of claim 185, wherein the seat assembly is a vehicle seat assembly.

187. The seat assembly of any of claims 185-186, further comprising a seat trim, an actuator, and / or a heat transfer layer attached to the polymer film.

188. A vehicle comprising a floor and a seat assembly according to any one of claims 185-187 mounted to the floor.

189. A mold tool comprising: A body, wherein the body defines a first section and a second section, the first section defines a first orifice so that the first section defines a first open space and a first enclosed portion, the second section defines one or more orifices so that the second section defines a second open space and a second enclosed portion, wherein (i) the first open space and the first enclosed portion are different from the second open space and the second enclosed portion, (ii) the orifices define a shape of a final product having a first profile and a second profile different from the first profile, (iii) the one or more orifices include an elongated orifice to define a polymer film, and / or (iv) the first orifice is different from the one or more orifices.

190. The mold tool of any one of claims 189 or 191-220, wherein the first section has an aperture density that is different from the aperture density of the second section.

191. A mold tool according to any one of claims 189 or 192-220, wherein the size of the first more than one orifices is different from the size of the one or more orifices.

192. The mold tool of any one of claims 189-191 or 193-220, wherein the first more than one orifices of the first section have an average diameter that is different from an average diameter of the one or more orifices of the second section.

193. A mold tool according to any one of claims 189-192 or 194-220, wherein the one or more orifices form at least one slit through the body.

194. A mold tool according to any one of claims 189-193 or 195-220, wherein the orifice of the mold tool is arranged to distribute molten thermoplastic resin.

195. A mold tool according to any one of claims 189-194 or 196-220, wherein the one or more orifices are arranged to define an outer perimeter of a cushion having a first bolster and a second bolster.

196. A mold tool according to any one of claims 189-195 or 197-220, wherein the one or more orifices is a second more than one orifice.

197. A mold tool according to any one of claims 189-196 or 198-220, wherein the first section defines a first area, the first open space defines a first open area, the second section defines a second area, and the second open space defines a second open area, wherein the ratio of the first open area to the first area is greater than the ratio of the second open area to the second area.

198. A mold tool according to any one of claims 189-197 or 199-220, wherein the one or more orifices include a through hole that is sized to match the entire perimeter of the gasket.

199. A mold tool according to claim 198, wherein the through hole is configured to receive molten thermoplastic resin and distribute the molten thermoplastic resin into more than one molten filament.

200. A mold tool according to claim 198 or claim 199, wherein the through hole is configured to retain the more than one molten filament.

201. A mold tool according to claim 190, wherein the first orifice density does not exceed 8 orifices per square inch.

202. A mold tool according to claim 189 or claim 201, wherein the second orifice density is at least 9 orifices per square inch.

203. A mold tool according to claim 192, wherein the first average diameter and the second average diameter differ by at least 0.4 mm.

204. A mould tool according to any one of claims 189-203 or 205-220, wherein there are more orifices per unit area in the first section than in the second section.

205. The mold tool of any one of claims 189-204 or 206-220, further comprising a template configured to cover the more than one orifices and / or at least a portion of the one or more orifices.

206. The mold tool of claim 205, wherein the template has a predetermined contour portion defining a cross-section of a portion of a vehicle interior component.

207. A mold tool according to claim 205 or claim 206, wherein the template has a predetermined contour portion defining a cross-section of a portion of the pad.

208. The mold tool of claim 207, wherein the first section is positioned in a position corresponding to a corresponding bolster portion of a seat cushion.

209. A mold tool according to any one of claims 198-200, wherein the through hole is formed into a seat pad.

210. The mold tool of any one of claims 198-200 or 209, wherein the through holes are configured to form a unitary nonwoven pad.

211. A mold tool according to any one of claims 198-200 or 209-210, wherein the through hole is formed to have a curved portion to form an integral nonwoven liner having a curved portion.

212. A mould tool according to any one of claims 198-200 or 209-211, wherein the through hole is provided with more than one bend of at least 12 mm radius.

213. A mold tool according to any one of claims 198-200 or 209-212, wherein the through hole is formed with a convex periphery to form a concave surface of the liner.

214. A dispensing system comprising a dispenser on which is disposed a mold tool according to any one of claims 189-213 or 215-220, so that during operation, the dispenser dispenses molten thermoplastic resin through the orifice of the mold tool.

215. A dispensing system according to claim 214, wherein the dispenser is an extruder for extruding the molten thermoplastic resin through the orifice of the die tool to form a molten thermoplastic filament.

216. The distribution system according to any one of claims 214-215 further includes a fluid chamber for receiving the molten thermoplastic filaments to block the flow of the molten thermoplastic filaments so that the filaments are bent to cross into an integral non-woven body in the shape of the entire periphery of the pad.

217. A dispensing system according to any one of claims 214-216, wherein the mold tool is aligned with the fluid chamber to cool the molten thermoplastic filaments into a unitary nonwoven pad.

218. A dispensing system according to any one of claims 214-217, wherein the mold tool defines a cooling channel formed through the mold tool to cool the molten thermoplastic filaments into a monolithic nonwoven mat.

219. A vehicle interior component comprising more than one interconnected polymer filaments dispensed by a mold tool according to any one of claims 189-218.

220. A pad comprising more than one interconnected polymer filaments dispensed by a mold tool according to any one of claims 189-219.

221. A method comprising: dispensing molten polymer resin through a die assembly having a first region defining first more than one apertures for dispensing molten polymer filaments and a second region defining one or more additional apertures for dispensing additional molten polymer members other than the molten polymer filaments, wherein the first region defines a first ratio of first blocked area to first open area that is different from a second ratio of second blocked area to second open area of ​​the second region; and The molten polymer filaments and the additional molten polymer members are cooled to form a web body comprising interconnected polymer filaments and having a first portion distinct from a second portion.

222. A method according to any one of claims 221 or 223-297, wherein the mesh body is a non-foam pad.

223. The method of any one of claims 221-222 or 224-297, wherein the mesh body is a vehicle interior component.

224. The method of any one of claims 221-223 or 225-297, wherein the additional molten polymer member is an additional polymer filament having a different shape, size, density and / or composition.

225. The method of any one of claims 221-224 or 226-297, wherein the molten polymer material is extruded through the die assembly.

226. A method according to any one of claims 221-224 or 227-297, wherein the first more than one pores or one or more additional pores define a perimeter in the shape of a final product.

227. The method of claim 226, wherein the final product is a seat pad.

228. The method of any one of claim 226 or claim 227, wherein the final product is a vehicle interior component.

229. The method of claims 221-228 or 230-297, wherein the first more than one pores define a first profile that is different from a second profile defined by the one or more additional pores.

230. The method of any one of claims 221-229 or 231-297, wherein the additional molten polymer member is a polymer film.

231. A method according to claim 230, wherein the polymer film is connected to the interconnected polymer filaments.

232. A method according to claim 230 or 231, wherein the polymer film is bonded to the interconnected polymer filaments.

233. A method according to any one of claims 221-232 or 234-297, wherein the molten polymer filaments are distributed into a medium interface defined by a first medium and a second medium, so that at least a subset of the molten polymer filaments are deflected and / or bent, so that at least a subset of the molten polymer filaments cross, interweave and / or combine while hardening to form the mesh body in the second medium.

234. The method of claim 233, further comprising removing the mesh body from the second medium and drying the mesh body.

235. A method according to claim 233 or claim 234, wherein the first medium is a gas and the second medium is a liquid.

236. The method of any one of claims 233-235, wherein the first medium is air and the second medium is water.

237. A method according to any one of claims 221-236 or 238-297, wherein the more than one pores are arranged at a first pore density and the one or more additional pores are arranged at a second pore density different from the first pore density.

238. The method of any one of claims 221-237 or 239-297, wherein the more than one pores define a first average diameter and the one or more additional pores define a second average diameter different from the first average diameter.

239. The method of any one of claims 221-238 or 240-297, wherein the first portion of the mesh body has a first hardness and the second portion of the mesh body has a second hardness different from the first hardness.

240. A method according to any one of claims 221-239 or 241-297, wherein a first thermoplastic polymer is dispensed through the orifices of the first region so that the first portion is a plastic mesh base of interconnected polymer filaments, and a second thermoplastic polymer is dispensed through the one or more orifices of the second region so that the second portion is a first plastic mesh pillow of interconnected polymer filaments attached to the plastic mesh base, the second thermoplastic polymer being different from the first thermoplastic polymer.

241. The method of claim 240, further comprising dispensing the first thermoplastic polymer, the second thermoplastic polymer, or a third thermoplastic polymer through a third region of the mold assembly such that a third portion of the mesh body is a second plastic mesh bolster.

242. A method according to claim 240 or claim 241, wherein the plastic mesh base includes a first side edge, a second side edge, a front edge, a rear edge, a first face and a second face, and the first plastic mesh bolster is attached to the plastic mesh base at the first edge.

243. The method of claim 242, wherein the second plastic mesh bolster is attached to the plastic mesh base at the second edge.

244. A method according to any one of claims 221-243 or 245-297, wherein the first more than one pores in the first region define a first open space per unit area, and the one or more additional pores in the second region define a second open space per unit area in the second region, such that the first open space per unit area is greater than the second open space per unit area.

245. The method according to any one of claims 221-244 or 246-297 further includes heating the polymer material to a molten state so that when the polymer material is received by and dispensed through the mold assembly, the polymer material forms the molten polymer filaments and / or the additional molten polymer components.

246. The method of any one of claims 221-245 or 247-297, further comprising surrounding the molten polymer filaments with a heating device operable to apply heat to the molten polymer filaments.

247. The method of any one of claims 221-246 or 248-297, further comprising introducing the molten polymer filaments and / or the additional molten polymer members into a cooling bath to form the web body of interconnected polymer filaments.

248. The method of any one of claims 233-236, wherein the second medium is disposed in the cooling bath.

249. The method of any one of claims 221-248 or 250-297, wherein the mold assembly comprises a mold plate.

250. A method according to any one of claims 221-249 or 251-297, wherein the mold assembly includes a template.

251. The method of any one of claims 221-250 or 252-297, wherein cooling occurs after the molten polymer filaments leave the die plate.

252. A method according to any one of claims 221-251 or 253-297, wherein the one or more additional apertures include apertures sized to match the entire periphery of the product, and the mold assembly retains the molten polymer filaments within the entire periphery of the product.

253. A method according to any one of claims 221-252 or 254-297, wherein there are more pores per unit area in the first region than there are pores per unit area in the second region.

254. A method according to any one of claims 221-253 or 255-297, wherein the first more than one pores comprise a diameter that is larger than a diameter of the one or more additional pores.

255. The method according to any one of claims 221-254 or 256-297 also includes masking a portion of the mold plate with a template including a predetermined contour so that the mesh body has a cross-section defined by the predetermined contour.

256. The method of any one of claims 221-255 or 257-297, wherein the second region includes a location corresponding to a location of an occupant sensor in the mesh body.

257. A method according to any one of claims 221-256 or 258-297, wherein the second area corresponds to a corresponding pillow area of ​​the cushion.

258. A method according to any one of claims 221-257 or 259-297, wherein the mold assembly includes a third region defining a second more than one pore, the third region defining a third ratio of a third blocked area to a third open area, and the third ratio is different from the first ratio and / or the second ratio.

259. A method according to claim 258, wherein the third open area per unit area is smaller than the first area per unit area and / or the second area per unit area.

260. The method of any one of claims 221-259 or 261-297, further comprising heating the entire periphery of the molten polymer filament.

261. The method of any one of claims 221-260 or 262-297, further comprising replacing the mold assembly or a portion thereof with a second mold assembly or a portion thereof.

262. A method according to any one of claims 221-260 or 263-297, wherein the mold assembly or a portion thereof comprises an interchangeable mold plate or template.

263. A method according to any one of claims 221-262 or 264-297, wherein the more than one pores form a size gradient or distribution gradient along the mold assembly so that the mesh body includes a hardness gradient.

264. A method according to claim 241 or claim 258, wherein the third region of the mold assembly is configured to provide a third portion of the mesh body, the third portion having a third hardness greater than the second hardness of the second portion of the mesh body, the second hardness greater than the first hardness of the first portion of the mesh body.

265. A method according to claim 264, wherein the second portion is disposed between the first portion and the third portion.

266. A method according to any one of claims 241, 258 or 264-265, wherein the third portion has a hardness different from the second hardness and within 10% of the first hardness.

267. The method of any one of claims 221-266 or 268-297, wherein the additional molten polymer component is dispensed on an outer surface of the mesh body.

268. The method of any one of claims 230-232 further comprises dispensing the film on an outer surface of the mesh body.

269. The method of any one of claims 221-266 or 268-297, wherein the additional molten polymer member is distributed between at least two subsets of the interconnected polymer filaments.

270. The method of any one of claims 230-232, further comprising distributing the film between at least two subsets of the interconnected polymer filaments.

271. The method of any one of claims 230-232, 268 or 270, further comprising forming pores through the membrane.

272. The method of any one of claims 221-271 or 273-297, wherein the one or more additional apertures comprise slits to distribute the membrane as the additional polymer component.

273. The method of any one of claims 221-272 or 274-297, further comprising removing the dispensing assembly or a portion thereof and installing a second dispensing assembly or a portion thereof.

274. The method of claim 273 further comprising dispensing different web bodies via the second dispensing assembly or a portion thereof.

275. The method of any one of claims 221-274 or 276, further comprising assembling a seat with the mesh body.

276. The method of any one of claims 230-232 or 268, wherein the membrane is an impermeable membrane.

277. The method of any one of claims 230-232, 268 or 276, further comprising attaching at least one of a seat trim, an actuator and / or a heat transfer layer to the membrane.

278. The method of claim 246, wherein the heating equipment comprises a rectangular heating structure to surround the molten polymer filaments as the molten polymer filaments exit the die assembly.

279. The method of any one of claims 221-278 or 281-297, wherein a heating device is attached to a side of the mold assembly.

280. The method of any one of claims 221-278 or 281-297, wherein heating equipment is attached to each side of the mold assembly.

281. The method of any one of claims 221-280 or 282-297, wherein the mold assembly is rectangular.

282. The method of any one of claims 246 or 278-280, wherein the heating equipment controls the temperature of the air surrounding the molten polymer filaments to a temperature of 60°C to 140°C.

283. The method of any one of claims 246, 278-280 or 282, wherein the heating equipment is positioned at least 100 mm to 150 mm from the molten polymer filaments.

284. A method according to any one of claims 221-283 or 285-297, wherein the molten polymer filaments include an outer portion disposed toward an outer edge of the mold assembly and an inner portion disposed inward from the outer portion, and the heating equipment is configured to heat the outer portion so that bonding between the molten polymer filaments of the outer portion is greater than bonding between the molten polymer filaments of the inner portion.

285. The method of any one of claims 221-284 or 286-297, wherein a first polymer material is dispensed through the first region of the mold assembly and a second polymer material is dispensed through the second region of the mold assembly, the second polymer material being different from the first polymer material.

286. A method according to claim 285, wherein a second polymer material is introduced into the mold assembly toward the outer edge of the mold assembly, and the first polymer material is introduced into the mold assembly inward from the second polymer material so that the additional molten polymer member at least partially surrounds the first polymer filament.

287. The method of any one of claims 221-286 or 288-297, further comprising dispensing a third polymer material through the mold assembly, the third polymer material being different from the first polymer material and / or the second polymer material.

288. The method of claim 287, wherein the third polymer material is different from the first polymer material and the second polymer material, and the first polymer material and the second polymer material are different from each other.

289. The method of any one of claims 221-289 or 290-297, wherein the first more than one pores collectively have an area that is larger than an area of ​​the one or more additional pores.

290. A method according to any one of claims 221-289 or 291-297, wherein the first one or more apertures form more than one nozzle, and the method further comprises closing the more than one nozzle or a subset thereof outside the one or more additional apertures.

291. The method of any one of claims 221-290 or 292-297, further comprising cooling the mold assembly.

292. The method of any one of claims 221-291 or 293-297, further comprising providing a casting having the one or more additional pores as the mold assembly.

293. The method of claim 292, wherein the mold includes cooling channels therethrough to cool the mesh body.

294. The method of claim 292 or claim 293, further comprising placing the mold in a cooling fluid, the cooling fluid cooling the mesh body.

295. A method according to any one of claims 221-294 or 296-297, wherein the mesh body also includes a perimeter with a concave profile.

296. A product formed by the method of any one of claims 221-295.

297. A vehicle interior component formed by the method according to any one of claims 221-296.

298. A system comprising: a forming assembly comprising a mold plate having a first region having more than one aperture and a second region having one or more additional apertures different from the more than one aperture; An extruder extrudes one or more polymeric materials through the forming assembly to form a mesh liner body.

299. The system of claim 298 further comprises a die plate for blocking a portion of the pores, a funnel for directing molten polymer filaments extruded through the die plate into the monolithic body and / or a cooling bath, a heating device for heating the molten polymer filaments, and / or a conveyor assembly for conveying the monolithic body through the cooling bath.

300. A system according to claim 298 or 299, wherein (i) the first region of the mold plate defines a first enclosed portion and a first open space, and the second region defines a second enclosed portion and a second open space, such that the first enclosed portion is different from the second enclosed portion and / or the first open space is different from the second open space, (ii) the first region defines a perimeter in the shape of a final product, (iii) the one or more additional pores include slits for dispensing a polymer film, (iv) a first pore density of the first region is different from a second pore density of the second region, and / or (v) a size of the more than one pore is different from a size of the one or more additional pores.

301. The system of any one of claims 298-300, wherein the first region defines a first profile and the second region defines a second profile different from the first profile.

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