Pad, manufacturing apparatus and manufacturing method

Abstract

A pad, a manufacturing apparatus, and a manufacturing method. The pad includes a mesh member including a set of filaments. Each member of the set of filaments is looped and bonded to at least one other member of the set of filaments. The mesh member defines a first side that includes a repeating non-planar profile.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 590,981, filed on October 17, 2023, the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present invention relates to a pad including a mesh member, a manufacturing device and a manufacturing method. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a perspective view of an example of a seat assembly.

[0006] Figure 2 is a perspective view of an example of a cushion for a seat assembly including a mesh member or mesh structure.

[0007] Figure 3 is a schematic diagram of an example of a manufacturing system for manufacturing a wire mesh structure.

[0008] Figure 4 is a side cross-sectional view of an example of a funnel that may be provided with the manufacturing system.

[0009] Figure 5 is relative to Figure 4 Move along multiple axes Figure 4 Side cross-sectional view of the funnel.

[0010] Figure 6 yes Figure 4 Plan view of the funnel.

[0011] Figure 7 is relative to Figure 6 Move along multiple axes Figure 6 Plan view of the funnel.

[0012] Figure 8 is a side cross-sectional view of another example of a funnel having independently movable sides.

[0013] Fig. 9 is shown with opposite sides moving towards each other Figure 8 Side cross-sectional view of the funnel.

[0014] Fig.10 is a partial side cross-sectional view of the funnel and wire mesh structure showing an example of a non-planar profile that repeats after exiting the funnel.

[0015] Fig.11 is a partial side cross-sectional view of the funnel and wire mesh structure showing another example of a non-planar profile that repeats after exiting the funnel.

[0016] Fig.12 is a partial side cross-sectional view of a funnel and wire mesh structure showing examples of non-planar and planar profiles that repeat after leaving the funnel.

[0017] Fig.13 is a partial side cross-sectional view of the funnel and wire mesh structure showing an example of a non-planar profile that repeats before exiting the funnel.

[0018] Detailed Description

[0019] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the detailed description that follows, many specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it is apparent to one of ordinary skill in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0020] It should be understood that the disclosed embodiments are merely exemplary, and that various forms and alternative forms are possible. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to implement the embodiments according to the present disclosure in various ways.

[0021] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0022] It should also be understood that, although in some cases, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact without departing from the scope of the various embodiments described. Both the first contact and the second contact are contacts, but they are not the same contact.

[0023] The terms used in the description of the various embodiments described herein are only used for the purpose of describing specific embodiments and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an" and "the" are intended to also include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and covers any and all possible combinations of one or more of the associated listed items. It should be further understood that when used in this specification, the terms "includes", "including", "comprises" and / or "comprising" specify the presence of the features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or groups thereof.

[0024] As used herein, the term "if" is optionally interpreted to mean "when" or "upon" or "in response to determining" or "in response to detecting," as appropriate to the context. Likewise, the phrases "if it is determined" or "if [the condition or event] is detected" are optionally interpreted to mean "upon determination" or "in response to determining" or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]," as appropriate to the context.

[0025] refer to Figure 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly, such as for land vehicles (such as cars, trucks, buses, etc.), or for non-land vehicles (such as aircraft or ships). For example, the seat assembly 10 for land vehicles can be shaped and sized to be used as a front driver or passenger seat, a second row of seats, a third row of seats, or other rear seats, and can include bucket seats, bench seats, or other seat styles as shown in the figure. In addition, the seat assembly 10 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 10 can be configured to be used for non-vehicle applications, such as furniture.

[0026] exist Figure 1 In the illustrated configuration, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool.

[0027] The seat bottom 20 is configured to receive a seated occupant and support the pelvis and thighs of the seat occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0028] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In some configurations, the seat bottom frame 30 includes a panel, a seat pan, a suspension pad, or a suspension wire on which the cushion 32 is disposed.

[0029] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat bottom frame 30. The cushion 32 and associated manufacturing methods will be discussed in more detail below.

[0030] The decorative cover 34 covers at least a portion of the cushion 32. In addition, the decorative cover 34 provides one or more visible exterior surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can be placed on the decorative cover 34. The decorative cover 34 is made of any suitable material or materials (e.g., fabric, leather, artificial leather, vinyl, or a combination thereof). The decorative cover 34 may include a plurality of decorative panels assembled in any suitable manner (e.g., by fusing or stitching). The decorative cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the decorative cover 34 may include decorative attachment features that are attached to the seat bottom frame 30, the cushion 32, or both to inhibit the removal of the decorative cover 34 and help the decorative cover 34 conform to the contours of the seat bottom frame 30, the cushion 32, or both. The decorative cover 34 can also be attached to the attachment pad.

[0031] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and adjacent to the rear side of the seat bottom 20. The seat back 22 extends in a generally upward direction away from the seat bottom 20. In some configurations, the seat back 22 is mounted to the seat bottom 20 and may pivot relative to the seat bottom 20. In other configurations, the seat back 22 is not mounted to the seat bottom 20. For example, a vehicle seat back may be mounted to a vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a decorative cover 44, and an optional headrest 46.

[0032] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In some configurations, the seat back frame 40 includes a panel, a base, a suspension pad, or a suspension wire on which the cushion 42 is disposed. It is also contemplated that in some configurations, the seat back frame 40 can be integrally formed with the seat bottom frame 30.

[0033] A cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be separate from the cushion 32 of the seat bottom 20. The cushion 42 and associated methods of manufacture will be discussed in greater detail below.

[0034] The decorative cover 44 covers at least a portion of the cushion 42. In addition, the decorative cover 44 provides one or more visible exterior surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can be placed on the decorative cover 44. The decorative cover 44 is made of any suitable material or materials (e.g., fabric, leather, artificial leather, vinyl, or a combination thereof). The decorative cover 44 may include a decorative panel or multiple decorative panels that are assembled in any suitable manner (e.g., by fusing or stitching). The decorative cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the decorative cover 44 may include decorative attachment features that are attached to the seat back frame 40, the cushion 42, or both to inhibit the removal of the decorative cover 44 and help the decorative cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both. The decorative cover 44 can also be attached to the attachment pad.

[0035] A headrest 46, if provided, is configured to support the head of a seat occupant. The headrest 46 is disposed on top of the seat back 22, or at an end of the seat back 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be integrally formed with the seat back 22.

[0036] refer to Figure 2 , an example of a cushion 50 is shown. For ease of reference, the cushions are generally indicated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 is applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0037] The pad 50 is a non-foam component or includes at least one non-foam component. The non-foam component is mainly called a mesh member, but may also be called a stranded member, an annular member, a tangled structure, a wire mesh structure, a mesh structure, a stranded net, an annular net, an entangled net or a mesh pad. Figure 2 , the cushion 50 is described as a non-foam component that does not include a foam component or foam material (e.g., urethane or polyurethane foam); however, it is contemplated that the cushion 50 may include a foam component or foam material in addition to the non-foam component to provide additional cushioning or localized cushioning to the seat occupant. For example, the foam material may be provided between the cushion 50 and a trim cover (e.g., trim cover 34, 44), the foam material may be provided on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam material provided to the cushion 50 or removing foam material from the cushion 50 may reduce weight and may improve support and comfort for the seat occupant. Additionally, removing the foam material may facilitate recycling of the cushion 50.

[0038] The pad 50 is described below without including the foam pad 50. In this case, the pad 50 is made of filaments 52 of a polymer material that are randomly looped, bent, curled or entangled and bonded together, as will be discussed in more detail below. Figure 10-13 An example of a filament 52 is shown in FIG. A filament 52 is bonded directly to another filament 52, rather than being bonded indirectly with a resin or other intermediate material.

[0039] Silk 52 can also be referred to as strand or thread, and is made of any suitable material or materials. In some configurations, silk 52 is made of polymer material or thermoplastic material, such as thermoplastic resins of polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based or its combination. As an example, polyethylene-based silk can be made of linear low-density polyethylene (LLPDE). Different from foam material, silk material can be recyclable, or more easily recyclable than foam material. It can also be imagined that silk 52 can include reinforcing fiber, and the reinforcing fiber may not be made of thermoplastic material.

[0040] In some configurations, the filament 52 can be a monofilament made of a single material. In some configurations, the filament 52 is made of multiple materials. For example, the filament 52 made of multiple materials can include a core made of a first thermoplastic material and a sheath (sheath) surrounding the core and made of a second thermoplastic material different from the first thermoplastic material. It is conceivable that the pad 50 can include a combination of a monofilament and a filament (the filament is made of multiple materials and is not a monofilament).

[0041] The randomly looped, bent, curled, or tangled filaments 52 are bonded together where one filament 52 contacts another filament 52 , thereby creating a lightweight, breathable pad (e.g., pad 32 and / or pad 42 ) or a mesh structure having openings or voids between the filaments 52 . Figure 3 Also shown is an example of a manufacturing system 60 for making a cushion or mesh structure. In this example, the manufacturing system 60 includes a material supply 70, an extruder 72, and a hopper 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0042] refer to Figure 3 The material supplier 70 holds the material feedstock to be extruded, such as solid beads, flakes, granules, pellets or powder made of the material. In some configurations, the material supplier 70 is configured as a container or a hopper. The material supplier 70 provides the material feedstock to the extruder 72.

[0043] The extruder 72 melts the material feedstock and extrude the material feedstock into a group of filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material through the barrel and helps heat the material due to the friction generated when the screw rotates. The material leaves the barrel under pressure and in a molten state and is transported to the die 80 of the extruder 72 under pressure.

[0044] The die 80 (which may also be referred to as a die plate or extrusion die) has a plurality of through holes or openings that form filaments, through which the molten material passes. A single filament 52 is extruded from each through hole. The filament 52 falls downward from the die 80 into the funnel 74 under the action of gravity.

[0045] The funnel 74 merges or groups the silk 52 into a more compact arrangement, wherein the silk is bent, curled or looped, and each silk 52 contacts and is bonded to at least one other silk 52. The funnel 74 has an inlet opening or funnel inlet and an outlet opening or funnel outlet that is smaller than the funnel inlet. The individually separated silk 52 enters the funnel inlet. When the silk 52 accumulates, the silk 52 is bent, curled or looped and moves in contact. The silk 52 moves toward the funnel outlet through the funnel 74. When the silk moves toward the funnel outlet, some silks can slide along the funnel 74 or along the intermediate sheet material arranged on the funnel 74. The combination between the silk 52 is formed at the contact point, and the opening or gap between the silk 52 exists in other positions where a silk 52 does not contact or is bonded to another silk 52. The entangled and bonded silk 52 passes the funnel outlet of the funnel 74 and enters the cooling tank 76. For ease of reference, the bonded silk 52 is referred to as a mesh member or a wire mesh structure 90.

[0046] Cooling tank 76 holds liquid, for example water or water and the mixture of another fluid.Liquid in cooling tank 76 helps to support the silk 52 of entanglement and combination, further compacts or consolidates into not too open or not too porous arrangement to limit silk 52, and keeps the desired porosity and density of wire mesh structure 90.Therefore, liquid provides some buoyancy or resistance, and these buoyancy or resistance can cause the extra bending, curling or looping of the silk 52 adjacent to liquid surface or in funnel 74, to further build wire mesh structure 90.When silk 52 is in liquid, liquid also cools silk 52.For example, liquid cools silk 52 from outside to solidify silk 52 and prevent silk 52 from combining in other position.At this moment, silk 52 is relatively stiff (stiff) and is no longer in plastic state, therefore roughly keeps shape, and is not plastic or reshaped when not being reheated.

[0047] The material handling subsystem 78 conveys the wire mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that help move the wire mesh structure 90 through the liquid and out of the liquid. In some configurations, a tractor conveyor 92 is provided in the cooling tank 76 to help pull the wire mesh structure 90 out of the funnel 74 and counteract the buoyancy of the wire 52.

[0048] One or more other rollers (e.g., roller 94) keep the screen structure 90 immersed in the liquid and guide the screen structure 90 through the cooling tank 76. For example, the roller 94 can guide the screen structure 90 toward a conveyor 96 and a shaker table 98 disposed outside the cooling tank 76. While the screen structure 90 is on the conveyor 96, the shaker table 98 shakes the screen structure 90 to remove the liquid. Alternatively or additionally, the screen structure 90 can be squeezed to remove the liquid, air can be blown to the screen structure 90 to remove the liquid, or both. It is also contemplated that the screen structure 90 can also be allowed to dry, or dried in ambient air.

[0049] The above-mentioned manufacturing system 60 is a continuous flow process, wherein, when the wire extrusion is not interrupted, the wire mesh structure 90 is formed into a continuous structure. After leaving the cooling tank 76, further processing of the wire mesh structure 90 is provided to cut the wire mesh structure 90 into individual pieces or billets for a single liner. This processing is performed by a cutting system of the manufacturing system 60. The cutting system can be of any suitable type. For example, the cutting system can use a blade, a knife, a hot knife, a saw, a fluid jet, etc. to cut the wire 52 of the wire mesh structure 90 into billets. The cutting system can be used to shape or contour the billet. It is also envisioned that the billet can be further shaped or contoured with other manufacturing processes, such as molding of the entire billet or a portion thereof.

[0050] Utilize above-mentioned process, pad 50 can be formed by a group of wires 52, wherein at least two members of this group of wires 52 are looped and bonded to each other.In one or more embodiments, each member of this group of wires 52 is looped and bonded to at least one other member of this group of wires.

[0051] refer to Figure 4 , an example of a funnel subsystem is shown. For ease of reference, the funnel subsystem is referred to as device 100. Device 100 is configured to vibrate one or more sides of funnel 74. Vibrating funnel 74 allows mesh member or wire mesh structure 90 to be provided with a repeating non-planar profile, as will be discussed in more detail below. In addition, vibrating funnel 74 can help prevent wire 52 from adhering to funnel 74 or to sheet 102, which can be optionally provided on funnel 74. In some configurations, device 100 includes funnel 74 and one or more actuators 104.

[0052] The funnel 74 includes a set of sides. In the illustrated configuration, the set of sides includes a first side 110, a second side 112, a third side 114, and a fourth side 116; however, it is contemplated that a greater or lesser number of sides may be provided. For example, the funnel 74 may have two or more sides that may or may not be movable relative to each other.

[0053] The set of sides cooperate to define an inlet opening 120 and an outlet opening 122 of the funnel 74. The inlet opening 120 is disposed at the top of the funnel 74, or at a location closer to the extruder 72 and the die 80 than the outlet opening 122. Thus, the filaments 52 enter the funnel 74 through the inlet opening 120 and exit the funnel 74 through the outlet opening 122. The filaments 52 exit the funnel 74 via the outlet opening 122. When the filaments 52 enter the inlet opening 120, the filaments 52 may not be tangled and combined, and when the filaments 52 exit the outlet opening 122, they may be tangled and combined.

[0054] The members of the set of sides can be arranged in various configurations. For example, one or more members of the set of sides can be angled or inclined so that the funnel 74 narrows in a direction extending from the inlet opening 120 toward the outlet opening 122. Thus, the inlet opening 120 can be larger than the outlet opening 122. In other words, the inlet opening 120 can have a larger area than the outlet opening 122, for example when viewed from above or along the Figure 4 The Z-axis may be a vertical axis or an axis oriented in a vertical direction as the wire 52 falls from the die 80 toward the inlet opening 120.

[0055] In some configurations, the sheet 102 is disposed on some or all of the members in the set of sides. The sheet 102 may be disposed within the funnel 74. The sheet 102 may extend along the upwardly facing surface of the side of the funnel 74. In some configurations, the upwardly facing surface extends between the inlet opening 120 and the outlet opening 122. For example, the sheet 102 may contact or engage the surface and may extend from the inlet opening 120 to the outlet opening 122 or toward the outlet opening 122. In this way, the sheet 102 separates the filaments 52 from the corresponding side of the funnel 74 so that one or more filaments 52 may contact the inwardly facing surface of the sheet 102, which faces the passage through the funnel 74 and is disposed opposite to the outwardly facing surface of the sheet 102, which faces the corresponding side of the funnel 74 and may contact the corresponding side of the funnel 74. It is also contemplated that a gap may be provided between the sheet 102 and the funnel 74 or the side of the funnel 74.

[0056] The sheet 102 can have any suitable configuration. For example, the sheet 102 can be made of any suitable material or materials, such as one or more polymeric materials, an example of which is nylon. The sheet 102 can be a film, a fabric, a woven layer, or a nonwoven layer. The sheet 102 can be liquid permeable or non-liquid permeable. In some configurations, a fluid 130 (such as a gas, a gas mixture (e.g., air), a liquid (e.g., water), or a combination thereof) is dispensed onto the sheet 102 to help prevent the filaments 52 from adhering to the sheet 102. For example, the fluid 130 can be dispensed or directed onto the inwardly facing surface of the sheet 102 facing toward the center of the funnel 74, an example of which is shown in FIG. Figure 4 and for clarity from Figure 5-Figure 7 In this configuration, the sheet 102 may or may not be liquid permeable.

[0057] In some configurations, the sheet 102 is liquid permeable and allows the fluid 130 to be distributed through or through the pores, holes or openings in the sheet 102, and thus allows the fluid 130 to pass through the sheet 102 from the outward-facing surface to the inward-facing surface, an example of which is shown in FIG. Figure 8 is best shown in the example, but for clarity the Fig. 9 It is also contemplated that sheet 102 may be omitted from some or all sides of funnel 74 , in which case fluid 130 may be dispensed onto the inwardly facing surface of funnel 74 .

[0058] It is contemplated that the fluid may be dispensed onto the inwardly facing surface of the sheet 102, the fluid may pass through the sheet 102 to the inwardly facing surface of the sheet 102, or a combination of the two in any configuration disclosed herein. Figure 4 Can have similar Figure 8 The configuration shown may or may not have Figure 8 Configuration shown.

[0059] One or more actuators 104 are provided to vibrate one or more sides of the funnel 74. The actuators 104 are configured to vibrate one or more sides of the funnel 74 along one or more axes (such as X, Y, and Z axes) that intersect each other and are arranged perpendicular to each other. Examples of such axes are shown in FIG. Figures 4 to 9 . The actuator 104 can be of any suitable type. For example, the actuator 104 can be configured as a tactile motor or a vibration motor. As some examples, the actuator 104 can be an eccentric rotating mass (ERM) vibration motor, a linear resident actuator (LRA), a solenoid actuator, etc. In some configurations, the actuator 104 is configured to move back and forth along at least one axis at a predetermined or variable distance and at a predetermined or variable frequency. As an example, the movement can occur at a distance of 10 mm or less (such as 0.5 mm) and at a frequency of 300 Hz or less (such as 60 Hz). The side of the vibrating funnel 74 transmits energy to at least a subset of the set of wires 52 (such as the wires 52 in contact with the corresponding side of the funnel 74 or the wires in contact with the sheet 102 disposed on the corresponding side of the funnel 74). Such wires 52 or portions thereof can be positioned along the periphery of the mesh member or mesh structure 90. The vibration transfers energy to at least a subset of the set of wires 52 and shapes at least a portion of the subset of the set of wires 52 to have a non-planar profile. For example, the vibration energy may cause the area of ​​the wires 52 engaged by the vibrating side of the funnel 74 to bend. The bending may produce a repeating pattern (e.g., a repeating profile along one or more sides) or a non-repeating pattern (a non-repeating profile along one or more sides). The non-planar profile or profile pattern may be a function of the vibration frequency of the corresponding side of the funnel 74 and produce a non-planar profile or contour along the perimeter of the mesh member or mesh structure 90, as will be discussed in more detail below.

[0060] In some configurations, such as Figure 4-Figure 7 In the configuration shown in , the funnel 74 is constructed so that a set of sides of the funnel 74 are fixedly positioned relative to each other. In this configuration, the actuator 104 vibrates the funnel 74, and all members of the set of sides move together or in unison along one or more axes. Figure 4-Figure 7 Vibration of the funnel 74 along three axes is shown; however, it should be understood that vibration may occur along a fewer number of axes, such as two axes or a single axis.

[0061] By comparison Figure 4 and Figure 5, can be best understood by the example of movement or vibration along the Y and Z axes. Figure 4 In FIG, the funnel 74 is shown in an example in a first position. Figure 5 In the example, the funnel 74 is relative to Figure 4 Move along the Y and Z axes. Figure 5 , the funnel 74 moves along the Y axis away from the actuator 104, or from relative to Figure 4 The funnel position shown in FIG. 1 is shifted to the right from the perspective shown in FIG. Figure 5 In, relative to Figure 4 From the perspective of the funnel position shown in FIG. 1 , the funnel 74 moves upward along the Z axis. It is contemplated that the actuator 104 can move the funnel 74 back along the corresponding axis. Figure 4 to complete an oscillation or vibration cycle along that axis.

[0062] By comparison Figure 6 and Figure 7 , can be best understood by the example of movement or vibration along the X and Y axes. Figure 6 , the funnel 74 is shown in a first position as viewed from above the funnel 74. Figure 7 In the example, the funnel 74 is relative to Figure 6 Move along the X and Y axes. Figure 7 , the funnel 74 moves along the Y-axis away from the actuator 104, or to the right from the perspective shown. Figure 7 In the example, the funnel 74 is relative to Figure 6 The funnel position in the X axis is moved along the X axis. It is conceivable that the actuator 104 can move the funnel 74 back along the corresponding axis. Figure 6 to complete an oscillation or vibration cycle along that axis.

[0063] Vibrating the funnel 74 and all sides of the funnel 74 in unison along one or more axes does not change the areas of the inlet opening 120 and the outlet opening 122. It is also contemplated that the areas of the inlet opening 120 and the outlet opening 122 may not change when at least one side of the funnel 74 is independently movable or vibrable relative to at least one other side of the funnel 74 but all sides of the funnel 74 are vibrated together or in unison.

[0064] Another example of a configuration of the funnel 74' is Figure 8 and Fig. 9 The funnel 74' in this configuration may share the characteristics of the previously described funnel 74, but the funnel 74' in this configuration is constructed so that at least one member of the set of sides is movable or vibrable (i.e., capable of being vibrated) relative to at least one other member of the set of sides of the funnel.

[0065] One or more actuators 104 can be operably connected to the funnel 74'. In some configurations, each member of a set of sides or each side of the funnel 74' can be coupled to a corresponding actuator 104, and the actuator 104 can be configured to vibrate the corresponding side of the funnel 74' relative to one or more other sides of the funnel 74', for example. For example, the first side 110, the second side 112, the third side 114, and the fourth side 116 can each be coupled to a corresponding actuator 104, and the corresponding actuator 104 causes one corresponding side to vibrate.

[0066] It is also contemplated that two or more sides may be fixedly positioned relative to each other, and that the actuator 104 may vibrate the sides fixedly positioned relative to each other together or in unison. As an example, a pair of sides (such as the first side 110 and the second side 112) may be vibrated relative to the third side 114 and the fourth side 116 by the corresponding actuator 104. The pair of sides vibrated by the corresponding actuator 104 may or may not be disposed adjacent to each other, such as when the pair of sides are disposed opposite to each other or another side of the funnel 74' that is not vibrated by the corresponding actuator 104 is disposed between the pair of sides. Vibrating the sides of the funnel 74' may change the area of ​​the inlet opening 120, the outlet opening 122, or both. Thus, the area of ​​the inlet opening 120, the outlet opening 122, or both may be variable rather than constant.

[0067] It is contemplated that one or more sides of the funnel 74' may be stationary and one or more other sides of the funnel 74' may vibrate relative to the stationary side of the funnel 74'.

[0068] The actuator 104 is configured to vibrate at least one associated funnel side along one or more axes. Figure 8 and Fig. 9 , the example of movement or vibration of different components of a set of sides of the funnel 74' along the Y axis can be best understood. Movement along the Y axis is used for illustrative purposes. Therefore, it should be understood that movement along the X axis, the Z axis, or any combination of the X, Y, and Z axes can be envisioned.

[0069] exist Figure 8 , the first side 110 and the second side 112 of the funnel 74 ′ are coupled to different actuators 104 and are shown in respective first positions.

[0070] exist Fig. 9, the first side 110 and the second side 112 are moved toward each other along the Y axis by the actuators 104, 104. Moving the first side 110 and the second side 112 toward each other reduces the distance between the first side 110 and the second side 112 and changes the shape or size of the inlet opening 120 and the outlet opening 122. For example, when the first side 110 and the second side 112 are moved toward each other and the third side 114 and the fourth side 116 (at Figure 8 and Fig. 9 When the distance between the first side 110 and the second side 112 is maintained or reduced, the area of ​​the inlet opening 120 and the area of ​​the outlet opening 122 are reduced. In this example, it is contemplated that the actuators 104, 104 can move the first side 110 and the second side 112 back to Figure 8 to complete an oscillation or vibration cycle.

[0071] It is also contemplated that the area of ​​the inlet opening 120, the area of ​​the outlet opening 122, or both may change when at least one side of the funnel 74' is vibrated relative to at least another side of the funnel 74', for example, at a different amplitude, a different frequency, a different direction, or a combination thereof, or when at least one side of the funnel 74' is vibrated relative to a stationary funnel side.

[0072] refer to Figure 10-12 , some examples of mesh members or mesh structures 90 having non-planar profiles are shown. In these figures and Fig.13 In the examples, one or more actuators 104 are omitted for clarity. In these examples, the non-planar profile is visible or present when the wire 52 has exited the exit opening 122 of the funnel 74, 74'.

[0073] The non-planar contour is disposed on one or more sides of the mesh member or wire mesh structure 90. In some configurations, the non-planar contour is a repeating non-planar contour, where the contour is repeated along the sides of the mesh member or wire mesh structure 90. For example, the repeating non-planar contour is not planar and may be wavy or have a wave shape.

[0074] The waveform includes any suitable wave shape, such as a sine waveform, a square waveform, a triangle waveform, a sawtooth waveform, etc.

[0075] For example, a sinusoidal waveform may be shaped similar to or vary according to a sinusoidal curve or a sine wave.

[0076] A square wave is a non-sinusoidal waveform that changes abruptly from one of two uniform values ​​or positions or axial distances to another on a periodic basis.

[0077] A triangular waveform is a non-sinusoidal waveform with a triangular shape that can be periodic and piecewise linear.

[0078] A sawtooth waveform is a non-sinusoidal waveform that resembles the teeth of a ramped or plain-toothed saw with zero rake angle.

[0079] The waveform or its part can be a periodic waveform. The periodic waveform repeats at a specific distance, or appears and reappears at regular or repeated distance intervals. The term non-planar profile is used to represent the profile or outline from wire to wire along one or more sides of the mesh member or wire mesh structure 90, as if the gap between the wires 52 does not exist, such as if the film is placed in contact with the wires 52 and bridges the gap between the wires 52 without sagging in the gap between the wires 52. The non-planar profile can be the profile of the outer side or peripheral side of the mesh member or wire mesh structure 90 along the cross section passing through the side. In some configurations, when observed along an axis (such as an axis perpendicular to the direction in which the wire 52 is extruded), a non-planar profile is visible along the entire side of the mesh member or wire mesh structure 90.

[0080] In the following example, vibration can occur in a horizontal plane, such as along the X-axis, the Y-axis, or a combination thereof. The vibration in the horizontal plane can produce a non-planar profile similar to a "vertical wave" in the funnel 74, 74' or after leaving the funnel 74, 74'. In some configurations, the non-planar profile provided improves the deformation resistance of the mesh member or wire mesh structure 90 at or near the corresponding side of the mesh member or wire mesh structure 90. The non-planar profile can make the mesh member or wire mesh structure 90 easier to grasp and fix, and can provide a decorative cover that helps to grasp the mesh member or filamentary mesh structure 90 or maintain its position.

[0081] refer to Fig.10 , shows an example of a mesh member or mesh structure 90 having a non-planar profile along opposing first and second sides 140, 142 of the mesh member or mesh structure 90. The solid wavy lines along the first and second sides 140, 142 represent the non-planar profile.

[0082] In this example, the non-planar profiles are shown as being sinusoidal and in phase with each other. Therefore, the distance D1 between the non-planar profile of the first side 140 and the non-planar profile of the second side 142 can be constant or substantially constant. In this example, as the non-planar profile of the second side 142 extends farther toward the central reference plane 150, the non-planar profile of the first side 140 extends farther away from the central reference plane 150, and conversely, as the non-planar profile of the second side 142 extends farther away from the central reference plane 150, the non-planar profile of the first side 140 extends farther toward the central reference plane 150. In some configurations, the central reference plane 150 is aligned with the Z axis or in the vertical direction of the filament 52 falling from the extruder 72.

[0083] Thus, when first side 140 moves to the left and away from center reference plane 150 as viewed from the perspective shown, second side 142 moves to the left and toward center reference plane 150 as viewed from the perspective shown. Conversely, when first side 140 moves to the right toward center reference plane 150 as viewed from the perspective shown, second side 142 also moves to the right and away from center reference plane 150.

[0084] Such a configuration may provide a funnel 74 with fixed sides by causing the funnel 74 to vibrate along the Y-axis, or side to side as viewed from the perspective of the double-arrowed line.

[0085] This configuration may also provide a funnel having a first side 110 and a second side 112, each having a corresponding actuator 104, or being fixedly positioned relative to each other and movable together relative to another member of the set of sides, such as a third side 114 or a fourth side 116. For example, a funnel may be used. Figure 8 and Fig. 9 The funnel 74 ′ shown in FIG. 7 provides such a configuration by actuating the first and second sides 110 , 112 in unison and in the same direction with their corresponding actuators 104 , 104 .

[0086] refer to Fig.11 , another example of a mesh member or wire mesh structure 90 having a non-planar profile along opposing first and second sides 140, 142 is shown. In this configuration, the non-planar profiles are shown as sinusoidal and out of phase with each other. Thus, the distance between the first side 140 and the second side 142 along an axis (such as the Y axis) varies as the mesh member or wire mesh structure 90 extends along the central reference plane 150.

[0087] In this example, when the non-planar profile of the second side 142 extends away from the central reference plane 150, the non-planar profile of the first side 140 extends away from the central reference plane 150, and vice versa when the non-planar profile of the second side 142 extends toward the central reference plane 150, the non-planar profile of the first side 140 extends toward the central reference plane 150. In this configuration, the distance D2 between the first side 140 and the second side 142 is greater than the distance D3 between the first side 140 and the second side 142. The distance D2 may be the position where the first side 140 and the second side 142 are farthest from each other or farthest from the central reference plane 150, and the distance D3 may correspond to the position where the first side 140 and the second side 142 are closest to each other or closest to the central reference plane 150.

[0088] A funnel 74' may be used and provided by simultaneously actuating the first side 110 and the second side 112 of the funnel 74' away from each other to increase the distance between the first side 140 and the second side 142 and simultaneously actuating toward each other to decrease the distance between the first side 140 and the second side 142. Fig.11 The configuration shown in .

[0089] refer to Fig.12 , shows an example of a mesh member or mesh structure 90 that includes a repeating non-planar profile along a first side 140 and does not include a repeating non-planar profile along a second side 142. In some configurations, the side that does not include a repeating non-planar profile is substantially planar, non-planar (e.g., curved, includes multiple non-planar segments, etc.) but does not have a repeating pattern in at least one axial direction along the side, or a combination thereof.

[0090] A funnel having at least one side that is movable relative to another side of the funnel may be used to provide a non-planar profile. Figure 8 and Fig. 9 The funnel 74' shown in Figure 7 provides this configuration by actuating the first side 110 toward and away from the central reference plane 150 while holding the second side 112 stationary. It should also be understood that this configuration can also be provided using a funnel that does not have an actuator 104 that actuates the opposite side, such as the second side 142. The planar profile of the second side 142 may be disposed parallel to the central reference plane 150 or may not be disposed parallel to the central reference plane 150.

[0091] It is also contemplated that one or more sides of the funnel 74' may be configured to facilitate movement along one or more sides (eg, Fig.12 The second side 142 (depicted in Figure 14) can be vibrated in a manner that aligns the filament 52 with a "smoother" profile or a flatter profile. For example, vibrating the funnel side at an appropriate frequency can help align the filament 52 in a generally vertical direction along the funnel side, thereby producing a flatter profile when viewed along the X-axis. It is contemplated that in some configurations, when viewed along the Y-axis, there may be a wavy profile from filament to filament or between filaments.

[0092] refer to Fig.13 , shows another example of a mesh member or wire mesh structure 90 having a non-planar profile. In this example, the non-planar profile is provided or present inside the funnel 74, 74', such as after the wire 52 enters the inlet opening 120 and before the wire 52 exits the outlet opening 122.

[0093] The non-planar profile may be provided on one or more sides of the mesh member or mesh structure 90. In this example, the non-planar profile is shown as being provided along or with the first side 140 and second side 142 of the mesh member or mesh structure 90 by moving the funnel 74, 74' or the first side 110 and second side 112 of the funnel 74, 74' along at least the Z-axis. The Z-axis may be disposed substantially parallel to the central reference plane 150. However, it is contemplated that the non-planar profile may be provided on a greater or lesser number of sides of the mesh member or mesh structure 90, on sides different from those illustrated, or a combination thereof.

[0094] In some embodiments, the non-planar profile is in any of the configurations previously described (such as Figure 4-Figure 12 In some embodiments, one or more funnel sides may also vibrate along one or more axes (eg, X-axis, Y-axis, or both) other than the Z-axis.

[0095] Moving or vibrating the first side 110 and the second side 112 along the Z-axis can cause the filament 52 to "bounce" and bend from the corresponding sides of the funnel 74, 74' to produce a non-planar profile. As a result, the non-planar profile or waveform can extend or repeat in a direction substantially parallel to the corresponding inwardly facing surfaces of the sides of the funnel 74, 74'. Vibrating the funnel 74, 74' in this manner can help prevent the filament from adhering to the sheet 102 (if present), or to prevent the filament from adhering to the sides of the funnel 74, 74' when the sheet 102 is not disposed on the sides of the funnel 74, 74'.

[0096] It is contemplated that vibration in the vertical direction or along the Z axis may allow sheet 102 to be omitted from some or all sides of funnel 74, 74'. It is contemplated that vibration in the vertical direction may cause mesh member or wire mesh structure 90 to have a non-planar profile when wire 52 exits exit opening 122 of funnel 74, 74'.

[0097] Vibrating the sides of the funnel 74' causes force to be transferred to at least a subset of the set of wires 52 that make up the mesh member or mesh structure 90. As a result, at least one member of the set of sides of the funnel 74, 74' is vibrated against the subset of the set of wires 52, causing the subset of the set of wires 52 to be formed to have a non-planar profile.

[0098] In some configurations, for example Figure 10-13In the configuration in, the wire 52 associated with the non-planar profile can be sufficiently cooled and hardened, for example by fluid 130 distributed at the funnels 74, 74', so that the non-planar profile exists when the wire 52 reaches the cooling tank 76, in which further cooling and hardening can occur.

[0099] Clause 1. An apparatus comprising: a funnel including a set of sides that cooperate to define an inlet opening and an outlet opening; and an actuator operably connected to the funnel, wherein at least one member of the set of sides is capable of vibrating by the actuator.

[0100] Clause 2. The apparatus of clause 1, wherein the set of sides are fixedly positioned relative to each other and the set of sides are capable of vibrating by the actuator.

[0101] Clause 3. The apparatus according to any preceding clause, further comprising a sheet disposed on at least one member of the set of sides and facing the inlet opening, wherein the sheet is capable of vibrating together with the at least one member of the set of sides.

[0102] Clause 4. Apparatus according to clause 1 or clause 3 when dependent on clause 1, wherein a first member of the set of sides is movable relative to a second member of the set of sides.

[0103] Clause 5. The apparatus of clause 4, wherein an area of ​​the inlet opening and an area of ​​the outlet opening are variable.

[0104] Clause 6. The apparatus of clause 4 or clause 5, further comprising a second actuator, wherein the first member in the set of sides is vibrated by the actuator, and the second member in the set of sides is vibrated with the second actuator.

[0105] Clause 7. An apparatus according to Clause 6, wherein the first member and the second member in the set of sides are arranged relative to each other, and the actuator and the second actuator are configured to respectively move the first member and the second member in the set of sides toward each other.

[0106] Item 8. A method comprising: extruding a group of filaments into a funnel, the funnel comprising a group of sides and an outlet opening defined by the group of sides; and vibrating at least one member of the group of sides of the funnel against a subset of the group of filaments, thereby forming the subset of the group of filaments to have a non-planar profile.

[0107] Clause 9. The method of clause 8, wherein the vibration changes the area of ​​the outlet opening.

[0108] Clause 10. The method of clause 8, wherein vibrating further comprises vibrating the set of sides without changing an area of ​​the outlet opening.

[0109] Clause 11. The method of any one of clauses 8 to 10, wherein extruding the set of filaments further comprises extruding the set of filaments through a die, and vibrating further comprises vibrating at least one member of the set of sides toward and away from the die while extruding the set of filaments.

[0110] Clause 12. The method of any one of Clauses 8 to 11, further comprising dispensing a fluid onto at least one member in the set of sides while vibrating the at least one member in the set of sides.

[0111] Clause 13. The method of any one of Clauses 8 to 12, further comprising dispensing a fluid onto a sheet disposed on at least one member of the set of sides while vibrating the at least one member of the set of sides.

[0112] Clause 14. The method of any one of Clauses 8 to 13, further comprising dispensing a fluid through a sheet disposed on at least one member in the set of sides while vibrating the at least one member in the set of sides.

[0113] Clause 15. A pad comprising: a mesh member including a set of filaments of thermoplastic material, wherein each member of the set of filaments is looped and bonded to at least one other member of the set of filaments, the mesh member defining a first side including a repeating non-planar profile.

[0114] Clause 16. The cushion of Clause 15, wherein the mesh member further comprises a second side and includes a second repeating non-planar profile.

[0115] Clause 17. The cushion of Clause 15, wherein the mesh member further comprises a second side disposed opposite the first side, and wherein the second side does not include the repeating non-planar contour.

[0116] Clause 18. The pad of any one of Clauses 15 to 17, wherein the repeating non-planar profile is a wave shape.

[0117] Clause 19. The pad of any one of Clauses 15 to 18, wherein the repeating non-planar profile is a periodic waveform.

[0118] Clause 20. The pad of Clause 19, wherein the repeating non-planar profile is a sinusoidal waveform.

[0119] Although exemplary embodiments are described above, this does not mean that these embodiments describe all possible forms of the present invention. Rather, the words used in this specification are descriptive and non-restrictive, and it should be understood that multiple changes can be made without departing from the spirit and scope of the present invention. In addition, the features of the embodiments of the various implementations can be combined to form other embodiments of the present invention.

Claims

1. A device comprising: a funnel including a set of sides cooperating to define an inlet opening and an outlet opening; and An actuator is operably connected to the funnel, wherein at least one member of the set of sides is capable of vibrating by the actuator.

2. The device according to claim 1, wherein The set of sides are fixedly positioned relative to each other, and the set of sides are capable of vibrating by the actuator.

3. The apparatus of claim 1, further comprising a sheet disposed on at least one member of the set of sides and facing the inlet opening, wherein the sheet is capable of vibrating together with the at least one member of the set of sides.

4. The apparatus of claim 1, wherein a first member of the set of sides is movable relative to a second member of the set of sides.

5. The device according to claim 4, wherein: The area of ​​the inlet opening and the area of ​​the outlet opening can be varied.

6. The apparatus of claim 4, further comprising a second actuator, wherein the first members in the set of sides are vibrated by the actuator, and the second members in the set of sides are vibrated with the second actuator.

7. The device according to claim 6, wherein: The first members and the second members in the set of sides are disposed opposite to each other, and the actuator and the second actuator are configured to respectively move the first members and the second members in the set of sides toward each other.

8. A method comprising: extruding a set of filaments into a funnel comprising a set of sides and an outlet opening defined by the set of sides; and At least one member of the set of sides of the funnel is vibrated against a subset of the set of wires to form the subset of the set of wires to have a non-planar profile.

9. The method according to claim 8, wherein: The vibration changes the area of ​​the outlet opening.

10. The method according to claim 8, wherein: Vibrating also includes vibrating the set of sides without changing an area of ​​the outlet opening.

11. The method according to claim 8, wherein: Extruding the set of filaments further comprises extruding the set of filaments through a die, and vibrating further comprises vibrating at least one member of the set of sides toward and away from the die while extruding the set of filaments.

12. The method of claim 8, further comprising dispensing a fluid onto at least one member in the set of sides while vibrating the at least one member in the set of sides.

13. The method of claim 8, further comprising dispensing a fluid onto a sheet disposed on at least one member in the set of sides while vibrating at least one member in the set of sides.

14. The method of claim 8, further comprising dispensing a fluid through a sheet disposed on at least one member in the set of sides while vibrating at least one member in the set of sides.

15. A pad comprising: A mesh member includes a set of filaments of thermoplastic material, wherein each member of the set of filaments is looped and bonded to at least one other member of the set of filaments, the mesh member defining a first side including a repeating non-planar profile.

16. The pad according to claim 15, wherein The mesh member also includes a second side and includes a second repeating non-planar profile.

17. The pad according to claim 15, wherein: The mesh member further includes a second side disposed opposite the first side, and the second side does not include the repeating non-planar profile.

18. The pad according to claim 15, wherein The repeating non-planar profile is a wave shape.

19. The pad according to claim 15, wherein: The repeating non-planar profile is a periodic waveform.

20. The pad according to claim 19, wherein The repeating non-planar profile is a sinusoidal waveform.

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