Tool with integrated fluid line for forming gasket assembly

Abstract

The invention relates to a tool with an integrated fluid line for forming a gasket assembly. A product is provided with a body having a non-rectangular cross-section, the body having a web of strands of expanded thermoplastic resin. A density of the web of strands around a perimeter of the non-rectangular cross-section is greater than a density within the perimeter. The periphery is provided with at least one recess formed therein.

Description

[0001] Cross - reference to related applications

[0002] This application claims priority to U.S. Application No. 18 / 390,516, filed December 20, 2023, and Danish Application No. PA202470199, filed July 30, 2024, the disclosures of which are incorporated herein by reference in their entireties. Technical field

[0003] Various embodiments relate to a cushion assembly for a seat assembly. Brief description of the drawings

[0005] Figure 1 is a front perspective view of a seat assembly according to an embodiment;

[0006] Figure 2 is according to an embodiment of Figure 1 a front partial perspective view of a cushion pad of the seat assembly;

[0007] Figure 3 is a front elevation schematic view of a system for manufacturing Figure 2 a seat cushion according to an embodiment;

[0008] Figure 4 is a front view of a cushion pad according to an embodiment;

[0009] Figure 5 is according to an embodiment of Figure 3 an enlarged front perspective view of a tooling plate of the system;

[0010] Figure 6 is Figure 5 a top partial cross - sectional view of the tooling plate;

[0011] Figure 7 is Figure 5 a partial cross - sectional perspective view of the tooling plate;

[0012] Figure 8 is Figure 3 an enlarged front perspective view of the system; and

[0013] Figure 9 is according to another embodiment of Figure 3 an enlarged front perspective view of a tooling plate of the system. Detailed description

[0015] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0016] 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. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one of ordinary skill in the art to practice the embodiments according to the disclosure in various ways.

[0017] "One or more" includes functions performed by one element, functions performed by more than one element (e.g., in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0018] It should also be understood that although the terms first, second, etc. are used in some cases herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, a first surface may be referred to as a second surface, and similarly, a second surface may be referred to as a first surface. The first surface and the second surface are both surfaces, but they are not the same surface.

[0019] The terminology used in the description of the various embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that, as used herein, the term "and / or" refers to and encompasses 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 "comprises", "comprising", "includes", and / or "including" specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0020] As used herein, the term "if" is optionally interpreted to mean "when" or "upon" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if [the condition or event] is detected" is optionally interpreted to mean "when determining" or "in response to determining" or "when [the condition or event] is detected" or "in response to detecting [the condition or event]", depending on the context.

[0021] Figure 1 Illustrated is a seat assembly 20 as a vehicle seat assembly 20 according to an embodiment. Although the vehicle seat assembly 20 is shown and described, any seat assembly 20 may be employed. The seat assembly 20 can be used for land vehicles, aircraft, watercraft, etc. The seat assembly 20 can also be used for office chairs, comfort chairs, etc.

[0022] The seat assembly 20 includes a seat bottom cushion 22 to support the pelvis and thighs of a seated occupant. The seat assembly 20 also includes a seat back cushion 24 to support the back and shoulders of the seated occupant. The seat assembly 20 further includes a headrest 26 to support the neck and head of the seated occupant. A trim cover 28 is disposed over the seat cushions 22, 24 and the headrest 26 to conceal the cushions 22, 24 and the headrest 26 and to provide a uniform and smooth contact surface for the occupant.

[0023] Reference Figure 2 , a product is shown. In the illustrated embodiment, the product is a seat cushion 22 shown removed from the seat assembly 20. The cushion 22 is provided with a body 30. According to an embodiment, the cushion 22 may be provided with a non-rectangular cross-section. The body 30 is composed of a network 32 of strands of expanded thermoplastic resin. The network 32 of strands is provided with three-dimensional filament loops extruded from a thermoplastic polymer. The thermoplastic polymer is composed of components selected from the group consisting of polyolefins, styrenic-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0024] Now refer to Figure 3 , the seat cushions 22, 24 are manufactured by a system 34 and a process of extruding a thermoplastic resin network. A hopper 36 houses the raw material to be extruded, such as solid pellets or granules of the material. The material may be provided by a plastic, such as linear low-density polyethylene (LLDPE). The material is fed from the hopper 36 to an extruder 38.

[0025] Extruder 38 melts and transports the material to die plate 40. In one non-limiting example, extruder 38 includes a barrel that houses a rotatable screw or auger and heating elements. Rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction generated as the screw rotates. The material exits extruder 38 in a molten state under pressure.

[0026] Die plate 40 extrudes the material into filaments 42. Die plate 40 may be arranged as described below relative to the extrusion direction of the final members 22, 24 produced by the die plate. More specifically, die plate 40 has a plurality of small circular through-holes or orifices through which the molten material passes. A single filament 42 is extruded from each die plate orifice. As described below, filaments 42 fall downward from the die plate into funnel 44 under system pressure and gravity. Funnel 44 may have a cross-sectional shape that is the same as or different from the shape defined in common with the orifices in die plate 40.

[0027] Funnel 44 helps the filaments 42 to coalesce or form a more compact arrangement in which the filaments 42 are bent or looped and each filament 42 contacts and bonds to at least one other filament 42. Funnel 44 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. Funnel 44 is narrower at the funnel outlet than at the funnel inlet. Individually separated filaments 42 enter the funnel inlet, the filaments 42 bend / loop and accumulate in contact with each other as they accumulate and slide downward along funnel 44 toward the funnel outlet, and the coalesced filament structure 46 exits the funnel outlet and directly enters the water tank.

[0028] Liquid tank 48 contains water 50, coolant, or other fluid and receives the coalesced filament structure 46 from funnel 44. The liquid 50 in bath 48 helps to temporarily support the coalesced filament structure 46 to prevent the filament structure from collapsing or condensing into an arrangement with few openings or pores and helps to maintain the desired porosity and density. Thus, water 50 provides some resistance that prompts the filaments 42 to undergo additional bending and looping to further construct the coalesced filament structure 46. Second, the liquid cools the filaments 42 from the outside to solidify the filaments 42 and prevent the filaments 42 from bonding at other locations.

[0029] Tank 48 includes various rollers and conveyors, such as traction conveyor 52, that help move the coalesced filament structure 46 through and out of the liquid 50. The speed of the rollers and conveyors can be controlled so that the coalesced filament structure 46 moves away from funnel 44 at a speed that depends on the speed at which the coalesced filament structure 46 exits funnel 44.

[0030] Other rollers, such as roller 54, help to keep the combined filament structure 46 submerged in the liquid 50 and guide the combined filament structure 46 through the liquid 50 towards the conveyor belt 56 and the vibrating table 58 disposed outside the tank 48. When the combined filament structure 46 is on the conveyor belt 56, the vibrating table 58 vibrates the combined filament structure 46 to remove the liquid. Additionally or alternatively, pressurized air can be blown onto the combined filament structure 46, and / or the combined filament structure 46 can be squeezed to remove the liquid 50. Then, the combined filament structure 46 can be cut into a desired size and shape.

[0031] Figure 4 is illustrated by Figure 3 The cushion 60 formed by the system 34. The cushion 60 is first extruded by the system 34 and then cut from the filament structure 46. The cushion 60 includes a body 30 formed by a network 32 of strands. The body 30 has a network 32 of strands of a certain density around the perimeter of a non-rectangular cross-section. The network 32 of strands around the perimeter consists of multiple rows of strands. The density of the network 32 of strands around the perimeter of the body 30 is greater than the density of the network 32 of strands within the perimeter of the body 30 to provide a contact surface around the perimeter. The perimeter also includes at least one recess 80, as shown in the illustrated embodiment. The recess 80 can be used as a groove for receiving other components of the seat assembly 20, such as a seat frame, pipes, wiring, etc.

[0032] The cushion 60 has Figure 4 the cross-section shown. The cross-section is non-rectangular such that the cushion 60 is extruded into the desired shape of the cushion 60 to avoid or minimize secondary transportation processes and material waste. The cushion 60 can be a seat cushion or can be part of a seat cushion assembled with other seat cushion parts. The cushion 60 can be used in any filling application, such as seat cushions, backrests, headrests, armrests, leg rests, etc.

[0033] Figures 5 - 8 is illustrated as being disposed in Figure 3 the funnel 44 of the system 34. The tool 62 is provided with an orifice 64, the size of which is designed to match the entire cross-section of the gasket 22. The tool 62 is provided with a non-rectangular cross-section to match the entire non-rectangular cross-section of the gasket 22. According to an embodiment, the tool 62 can be 3D printed. According to an embodiment, the tool 62 can be made of a polymeric material. Alternatively, the tool can be formed of aluminum, stainless steel, or any suitable metal or alloy.

[0034] Tool 62 is used in the process of manufacturing gasket 22. The process first includes distributing multiple outer strands 66 of molten thermoplastic resin through orifice 64 of tool 62, and the multiple outer strands 66 engage leading edge 68 of tool 62. Leading edge 68 is shown as an angled chamber of tool 62. At the same time, multiple inner strands 70 of molten thermoplastic resin are distributed through orifice 64 of tool 62 without engaging leading edge 68 of tool 62. Then, a fluid (such as water) is distributed through fluid line 72 passing through tool 62 to cool the tool and cool strands 66 and 70 into a cured web. The fluid is distributed through fluid line 72 to cool tool 62 and thus cool strand 70. The fluid also engages leading edge 68 before being distributed to orifice 64 of tool 62.

[0035] Tool 62 includes multiple protrusions 82 extending within orifice 64 for forming recess 80. Tool 62 may also include multiple leading edges 84 that are inclined at a steeper slope than leading edge 68 to cooperate with the formation of recess 80.

[0036] Fluid line 72 surrounds the perimeter of leading edge 68 and branches towards orifice 64 of tool 62. Fluid line 72 forms a continuous loop to achieve uniform fluid distribution. Fluid line 72 is connected to multiple inlets 74 formed around tool 62 to supply water to fluid line 72. Inlets 74 are also connected to multiple outlets 76 to distribute the fluid through orifice 64. Outlets 76 are formed through protrusions 82 to distribute the fluid into recess 80 in gasket 60. As Figure 7 shown, additional fluid lines 86 are provided in tool 62 to convey the fluid to outlets 76.

[0037] Before distributing multiple outer strands 66 of molten thermoplastic resin, leading edge 68 can be lubricated with fluid first. Leading edge 68 can also be lubricated during the distribution of multiple outer strands 66 of molten thermoplastic resin. Leading edge 68 is also provided with fabric 78 that is displaced along leading edge 68, as Figure 8 shown. Fabric 78 can also be lubricated before or during the distribution of outer strands 66.

[0038] Figure 9 A tool 88 disposed in the funnel 44 of the system 34 shown in Figure 3 is shown according to another embodiment. Tool 88 is provided with an orifice 90 sized to match the entire cross-section of gasket 22. Tool 88 is provided with a non-rectangular cross-section to match the entire non-rectangular cross-section of gasket 22. According to an embodiment, tool 88 can be three-dimensionally printed. According to an embodiment, tool 88 can be made of a polymer material.

[0039] Tool 88 is used in a process for manufacturing gasket 22. The process first includes dispensing multiple outer strands 66 of molten thermoplastic resin through orifices 90 of tool 88, and the multiple outer strands 66 engage leading edge 92 of tool 88. The leading edge 92 is shown as an angled chamber of tool 88. At the same time, multiple inner strands 70 of molten thermoplastic resin are dispensed through orifices 90 of tool 88 without engaging the leading edge 92 of tool 88. Then, a fluid (such as water) is dispensed through fluid line 94 passing through tool 88 to cool the tool and cool strands 66, 70 into a cured web. The fluid is dispensed through fluid line 94 to cool tool 88 and thus cool strand 70. The fluid also engages the leading edge 92 before being dispensed into orifices 90 of tool 88.

[0040] Fluid line 94 surrounds the perimeter of leading edge 92 and branches towards orifices 90 of tool 88. Fluid line 94 forms a continuous loop to achieve consistent fluid distribution. Fluid line 94 is connected to multiple inlets 96 formed around tool 88 to supply water to fluid line 94. The inlets 96 can also be connected to multiple outlets to dispense the fluid through orifices 90. The leading edge 92 can be lubricated by the fluid prior to dispensing the multiple outer strands 66 of molten thermoplastic resin. The leading edge 92 can also be lubricated during dispensing of the multiple outer strands 66 of molten thermoplastic resin.

[0041] In at least a first clause that can be combined with any of the following clauses or can be not combined with any of the following clauses, the product is provided with a body having a non-rectangular cross-section, and the body is provided by a web of strands of expanded thermoplastic resin. The density of the web of strands around the perimeter of the non-rectangular cross-section is greater than the density of the web of strands within the perimeter. The perimeter includes at least one recess formed therein.

[0042] According to a second clause, there is provided a product according to any one of the foregoing clauses or the following clauses, wherein the density of the web of strands around the perimeter of the non-rectangular cross-section includes multiple rows of strands.

[0043] According to a third clause, there is provided a seat assembly including a seat frame and a cushion. The size of the body according to any one of the foregoing clauses or the following clauses is designed to provide the cushion.

[0044] In a fourth clause (which may or may not be combined with any of the foregoing clauses or the following clauses), a method of manufacturing a product, the method distributing multiple strands of molten thermoplastic resin through a tool having an orifice, the size of the orifice being designed to match the entire cross-section of the product. The leading edge of the tool engages the outer multiple strands of the molten thermoplastic resin. The inner multiple strands of the molten thermoplastic resin pass through the orifice. The inner multiple strands of the molten thermoplastic resin pass through the orifice spaced inwardly from the leading edge. A dispensing fluid passes through a fluid line formed through the tool.

[0045] According to a fifth clause, there is provided a method according to any of the foregoing clauses or the following clauses, wherein the tool has a non-rectangular cross-section that matches the entire non-rectangular cross-section of the product.

[0046] According to a sixth clause, there is provided a method according to any of the foregoing clauses or the following clauses, including dispensing a fluid from the fluid line into the orifice of the tool.

[0047] According to a seventh clause, there is provided a method according to any of the foregoing clauses or the following clauses, including dispensing a fluid along the leading edge from the fluid line.

[0048] According to an eighth clause, there is provided a method according to any of the foregoing clauses or the following clauses, including lubricating the leading edge before dispensing the molten thermoplastic resin.

[0049] According to a ninth clause, there is provided a method according to any of the foregoing clauses or the following clauses, including lubricating a fabric displaced along the leading edge before or during dispensing the molten thermoplastic resin.

[0050] According to a tenth clause, there is provided a product formed by a method according to any of the foregoing clauses or the following clauses.

[0051] According to an eleventh clause, there is provided a product according to any of the foregoing clauses or the following clauses, and a seat cushion is also provided.

[0052] According to a twelfth clause, there is provided a method according to any of the foregoing clauses or the following clauses, including installing the product as a cushion in a seat assembly.

[0053] According to a thirteenth clause, a seat assembly is manufactured by a method according to any of the foregoing clauses or the following clauses.

[0054] According to a fourteenth clause, there is provided a method according to any of the foregoing clauses or the following clauses, including the step of machining the body of the tool from a raw material.

[0055] In accordance with Article 15, a method as described in any one of the foregoing clauses or the following clauses is provided, including a three-dimensional printing tool.

[0056] In Article 16 (which may or may not be combined with any one of the foregoing clauses or the following clauses), a tool is provided that includes a tool body having a through-orifice and a leading edge surrounding the orifice. The through-orifice is sized to match the entire perimeter of a product, and the leading edge and the through-orifice are sized to receive molten thermoplastic resin as multiple dispensing strands. wherein the through-orifice of the tool is sized to hold the multiple dispensed strands within the entire perimeter of the product, and wherein a fluid line is formed through the tool to cool the tool and the multiple strands.

[0057] In Article 17, a tool as described in any one of the foregoing clauses or the following clauses is provided, wherein the through-orifice of the tool is non-rectangular and has a non-rectangular cross-section.

[0058] In Article 18, a tool as described in any one of the foregoing clauses or the following clauses is provided, and the tool has a plate.

[0059] In Article 19, a tool as described in any one of the foregoing clauses or the following clauses is provided, and the tool has a fluid fitting surrounding the perimeter.

[0060] In Article 20, a tool as described in any one of the foregoing clauses or the following clauses is provided, and the tool has a valve.

[0061] In Article 21, a tool as described in any one of the foregoing clauses or the following clauses is provided, and the tool has a fabric mounted on the tool.

[0062] In Article 22, a tool as described in any one of the foregoing clauses or the following clauses is provided, wherein the tool is formed of a polymeric material.

[0063] In Article 23, a tool as described in any one of the foregoing clauses or the following clauses is provided, wherein the tool is three-dimensionally printed.

[0064] In Article 24, a tool as described in any one of the foregoing clauses or the following clauses is provided, wherein the fluid line surrounds the perimeter of the leading edge.

[0065] In Article 25, a tool as described in any one of the foregoing clauses or the following clauses is provided, wherein the fluid line branches towards the orifice of the tool.

[0066] In Article 26, a tool as described in any one of the foregoing articles or the following articles is provided, wherein a fluid pipeline forms a continuous loop to achieve uniform water distribution.

[0067] In Article 27, a tool as described in any one of the foregoing articles or the following articles is provided, which has a plurality of inlets to supply water to the fluid pipeline.

[0068] In Article 28, a tool as described in any one of the foregoing articles is provided, which has a plurality of outlets to filter the fluid passing through the orifice.

[0069] Although various embodiments are described above, this does not mean that these embodiments describe all possible forms according to the present disclosure. In this regard, the words used in the specification are descriptive rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. In addition, the features of the various embodiments can be combined to form additional embodiments according to the present disclosure.

Claims

1. A product comprising: a body having a non-rectangular cross-section, the body comprising a network of strands of expanded thermoplastic resin; wherein a density of the mesh of strands around a perimeter of the non-rectangular cross-section is greater than a density of the mesh of strands within the perimeter, and wherein the perimeter includes at least one recess formed therein.

2. The product according to claim 1, wherein The density of the web of strands around the perimeter of the non-rectangular cross-section includes multiple rows of strands.

3. A seat assembly comprising: Seat frame; and A cushioning pad, wherein the body according to claim 1 is dimensioned to provide said cushioning pad.

4. A method of manufacturing a product, comprising: dispensing a plurality of strands of molten thermoplastic resin through a tool having an orifice sized to match the overall cross-section of the product; engaging a leading edge of the tool with the outer plurality of strands of the molten thermoplastic resin; passing said plurality of strands of said molten thermoplastic resin through said orifice; passing the inner plurality of strands of molten thermoplastic resin through the orifice spaced inwardly from the leading edge; and Fluid is dispensed through fluid lines formed through the tool.

5. The method according to claim 4, wherein: The tool has a non-rectangular cross-section that matches the overall non-rectangular cross-section of the product.

6. The method according to claim 4, further comprising: Fluid is dispensed from the fluid line into the orifice of the tool.

7. The method according to claim 4, further comprising: Fluid is dispensed from the fluid line along the leading edge.

8. The method according to claim 4, further comprising: The leading edge is lubricated prior to dispensing the molten thermoplastic resin.

9. The method according to claim 4, further comprising: The fabric displaced along the leading edge is lubricated prior to or during dispensing of the molten thermoplastic resin.

10. A product formed by the method of claim 4.

11. The product of claim 10 further comprising a seat cushion.

12. The method according to claim 4, further comprising: The product is installed as a cushion to a seat assembly.

13. A seat component manufactured according to the method of claim 12.

14. The method of claim 4, further comprising the step of machining the body of the tool from stock material.

15. The method of claim 4, further comprising three-dimensional printing the tool.

16. A tool comprising a tool body having a through aperture and a leading edge surrounding the aperture, the through aperture being sized to match the entire perimeter of a product, the leading edge and the through aperture being sized to receive molten thermoplastic resin as a plurality of dispensed strands, wherein: The through aperture of the tool is sized to retain the plurality of distributed strands within the entire perimeter of the product, and wherein a fluid line is formed through the tool to cool the tool and the plurality of strands.

17. The tool according to claim 16, wherein: The through-going aperture of the tool is non-rectangular, having a non-rectangular cross-section.

18. The tool of claim 16, wherein: The tool body also includes a plate.

19. The tool of claim 16, wherein: The tool also includes a fluid fitting surrounding the perimeter.

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