Cushion assembly

Abstract

A product provided with a body having a non-rectangular cross-section, the body being formed from a plurality of strands of expanded thermoplastic resin. A density of the plurality of strands around a perimeter of the non-rectangular cross-section is greater than a density within the perimeter to provide a contact surface around the perimeter.

Description

Cross - Reference to Related Applications

[0001] This application claims priority to Danish Patent Application Serial No. PA202370425, filed on August 21, 2023, which in turn claims priority to U.S. Provisional Patent Application Serial No. 63 / 435,952, filed on December 29, 2022. Technical Field

[0002] Various embodiments relate to a cushion assembly for a seat assembly. Brief Description of the Drawings

[0003] Figure 1 is a front perspective view of a seat assembly according to an embodiment; Figure 2 is according to an embodiment of Figure 1 a front partial perspective view of the cushion of the seat assembly; Figure 3 is for manufacturing Figure 2 a front elevation schematic view of a system for a seat cushion; Figure 4 is a front elevation view of the cushion; Figure 5 is Figure 3 an enlarged front perspective view of the tool plate of the system; Figure 6 is Figure 3 an enlarged front perspective view of the system. Detailed Description

[0004] 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 those 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.

[0005] It should be understood that the disclosed embodiments are merely exemplary, and that various 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 variously utilize the embodiments in accordance with the present disclosure.

[0006] "One or more" includes functions performed by one component, functions performed by more than one component (e.g., in a distributed manner), several functions performed by one component, several functions performed by several components, or any combination of the above.

[0007] It should also be understood that although the terms first, second, etc. are used in some cases herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another. For example, a first contact can be referred to as a second contact, and similarly, a second contact can 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.

[0008] The terms used in the description of the various embodiments herein are for the purpose of describing particular embodiments only and are not intended to be limiting. As used in the description of the various embodiments described 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.

[0009] As used herein, the term "if" is optionally interpreted to mean "when", "upon", "in response to determining", or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if detected [the stated condition or event]" is optionally interpreted to mean "when determining", "in response to determining", "when detecting [the stated condition or event]", or "in response to detecting [the stated condition or event]", depending on the context.

[0010] 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 illustrated and described, any seat assembly 20 can be employed. The seat assembly 20 can be used for land vehicles, aircraft, boats, etc. The seat assembly 20 can also be used for office chairs, comfort chairs, etc.

[0011] The depicted 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. A trim cover 26 is disposed over the seat cushions 22, 24 to conceal the cushions 22, 24 and provide a uniform and smooth contact surface for the occupant.

[0012] Now referring Figure 2 , one of the seat cushions 22 is shown partially separated from the seat assembly 20. The seat cushion 22 is formed of multiple strands 28 of extruded, expanded thermoplastic resin. The seat cushion 22 also forms a layer or film 30 of the extruded thermoplastic resin strands 28 that are densified, bonded to the multiple strands 28, and formed integrally with the multiple strands 28.

[0013] Now referring Figure 3 , the seat cushions 22, 24 are manufactured by a system 34 and a process of extruding a thermoplastic resin web. A hopper 36 holds a raw material of the material to be extruded, such as solid particles or beads as the material. The material can be provided by a plastic (e.g., linear low density polyethylene (LLDPE)). The material is fed from the hopper 36 to an extruder 38.

[0014] The extruder 38 melts the material and transports the material to a die plate 40. In one non - limiting example, the extruder 38 includes a barrel that receives a rotatable screw and a heating element. 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 exits the extruder 38 under pressure and in a molten state.

[0015] The die plate 40 extrudes the material into filaments 42. The die plate 40 can be provided as described below, depending on the extrusion direction relative to the final members 22, 24 produced therefrom. More specifically, the 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 hole. The filaments 42 fall from the die plate down into a funnel 44 under the action of system pressure and gravity, as described below. The funnel 44 can have a cross - sectional shape that is the same as or different from the shape jointly defined by the orifices in the die plate 40.

[0016] The funnel 44 helps the filaments 42 to merge or combine into a more compact arrangement in which the filaments 42 are bent or looped and each filament 42 contacts and binds to at least one other filament 42. The funnel 44 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. The funnel 44 is narrower at the funnel outlet than at the funnel inlet. Individual separate filaments 42 enter the funnel inlet, and as the filaments gather and slide down the funnel 44 towards the funnel outlet, the filaments 42 bend / loop and move into contact with each other, and the combined filament structure 46 exits the funnel outlet and immediately enters the water tank.

[0017] The liquid tank 48 contains water 50, coolant or other fluid and receives the combined filament structure 46 from the funnel 44. The liquid 50 in the bath 48 helps to temporarily support the combined filament structure 46 to prevent the filament structure from collapsing or compacting into a less open or less porous arrangement, and helps to maintain the desired porosity and density. Thus, the liquid 50 provides some resistance that causes additional bending and looping of the filaments 42 to further construct the combined filament structure 46. Secondly, the liquid 50 cools the filaments 42 from the outside to solidify the filaments 42 and prevent the filaments 42 from binding in other locations.

[0018] The tank 48 includes various rollers and conveyors, such as a traction conveyor 52, that help to move the combined filament structure 46 through and out of the liquid 50. The roller and conveyor speeds can be controlled so that the combined filament structure 46 moves away from the funnel 44 at a speed that is related to the speed at which the combined filament structure 46 exits the funnel 44.

[0019] 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 a conveyor belt 56 and a 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. Pressurized air can additionally or alternatively be blown towards the combined filament structure 46, and / or the combined filament structure 46 can be squeezed to remove the liquid 50. The combined filament structure 46 can then be cut into a desired size and shape.

[0020] Figure 4 Illustrated is a cushion 60 formed by Figure 3 system 34. The cushion 60 is extruded from the system 34 and then cut from the filament structure 46. The cushion 60 includes a body formed by multiple strands 28 to form a one-piece body. The cushion 60 has Figure 4The 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 forming processes and waste of material. The cushion 60 can be a seat cushion or can be part of a seat cushion that is assembled with other seat cushion parts. The cushion 60 can be used for any padding application such as seat cushions, backrests, headrests, armrests, leg rests, etc.

[0021] Figure 5 Illustrated is a tool 62 disposed in a funnel 44 of a system 34. Continuing to refer to Figure 3 the tool 62 is shown as a plate 62, referred to as a funnel plate 62. An orifice 64 is formed through the plate 62 to direct and converge strands or molten filaments 42 of a thermoplastic resin into a cooling chamber 48. The through-orifice 64 is sized to match the overall profile or perimeter of the cushion 60 when viewed in the direction of the Figure 5 view. Thus, the molten resin strands 42 are collected, directed, and cooled into the cushion 60. The plate 62 shapes a mesh of the molten resin strands 42 into the overall profile of the liner 22 as the strands 42 buckle, loop, and cross. The plate 62 shapes the mesh before the mesh solidifies into a nonwoven mesh assembly of the cushion 60. Figure 4 The tool plate 62 includes a leading edge 66 that surrounds the through-orifice 64 at the filament input end of the plate 62. The leading edge 66 can be chamfered, rounded, etc. as shown. The leading edge 66 directs the filament strands 42 into the plate orifice 64.

[0022] The tool plate 62 is shown covered with a fabric material 68 that covers the tool plate 62 for receiving and contacting the filaments 42. The fabric material 68 is lubricated to facilitate cooling and resistance to the filaments 42 as the filaments 42 travel along the leading edge 66 of the plate 62. The fabric material 68 is used to hold a lubricant on the leading edge 66 during the dispensing operation. The lubricant can be water 50 or other material consistent with the liquid 50 in the tank 48. The system 34 includes a fluid line 70 to convey the lubricant from the tank 48 to the fabric material 68.

[0023] Figure 6 Illustrated is the tool plate 62 installed in the funnel 44 of the system 34.

[0024] Figure 6Shows an uninterrupted flow of filaments 42 of molten thermoplastic resin from an extrusion die 40. Unless otherwise stated, 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 capable of flowing through the components of system 34. For example, the molten material is still capable of flowing through the die plate 40, but the molten material may be very viscous and start to solidify. Once the solid particles of the polymeric material are melted in the extruder 38, the material begins to cool when the molten material is no longer agitated by the extruder screw and is away from any heaters. At different nodes in process 34, the material may have a higher or lower viscosity, but if it is still partially molten and capable of flowing (including flowing only slowly), the term "molten" applies herein.

[0025] In Figure 6 it, the molten strands 28 and the film 30 are shown entering the funnel plate 62 to advance through and reach the cooling chamber 48. In the cooling chamber 48, the flow of the filaments 42 is impeded by the fluid and buckles, bends, and joins with each other. A portion of the strand filaments 42 is further impeded and buckles along the leading edge 66 to provide a denser density of strands 28 around the perimeter (compared to the density of the filaments offset inward from the perimeter). The denser strands 28 around the perimeter form the film or skin 30. The filaments 42 cool and solidify within the cooling chamber 48 into the strands 28 and the film 30, and the strands 28 and the film 30 form a one-piece body as the cushion 60.

[0026] The extrusion die 40 includes a plurality of nozzles 72 that exceed the total area of the through-orifices 64 of the plate 62 such that the filaments 42 engage the fabric 68 along the leading edge 66. The nozzles 72 are arranged in an array, and the number of rows of filaments 42 that engage the leading edge 66 can be selected. For example, one row of filaments 42 engages the leading edge 66 and converges on the edge 66, resulting in a denser skin 30 than the remaining strands 28. If two rows of filaments 42 engage the leading edge 66, a denser (or medium-thickness) skin 30 is produced. Similarly, when three rows of filaments 42 are aligned around the perimeter to engage and converge at the leading edge 66, a thick skin 30 is produced. Additionally, if all the nozzles 72 are aligned with the through-orifices 64, little or no skin 30 is formed around the perimeter.

[0027] The outer skin 30 provides surface tension for the continuous seating surface on the cushion 22, similar to the skin along a foam cushion, for the support and comfort of the occupant. The skin 30 also provides a surface for attaching other seating components by adhesives, hook-and-loop fasteners, or the like. As Figure 2As shown in the figure, another layer 74 is attached to the outer skin 30. According to one embodiment, layer 74 is the decorative cover 26. According to another embodiment, layer 74 is the actuator 74, such as the airbag assembly 74. According to yet another embodiment, layer 74 is the heat transfer layer 74, such as the heating pad 74. Layer 74 can also be a decorative component 74 or a tab for attaching to other decorative components, such as the carrier 76 ( Figure 1 ). Layer 74 can also be a support member 74 for attaching to the seat frame 78 ( Figure 1 ).

[0028] The seat cushion is typically molded from a foam material. The foam cushion requires special tools to mold each cushion part. Compared with the prior art die tools, Figure 4 's seat cushion 60 utilizes the special tooling plate 62 of FIG. 7. Figure 3 and Figure 6 's system 34 includes a flexible device adapted to manufacture a variety of cushions with a variety of tooling plates. When used with the tooling plate 62, the nozzles 72 outside the perimeter of the leading edge 66 are closed, such that the extruded filaments 42 are dispensed into the orifices 64 and the leading edge 66. The closing or opening operation of each nozzle 72 can be adjusted for each tooling plate 62. Similarly, the number of rows of nozzles 72 outside the orifices 64 can be adjusted to determine the strand density at the skin 30.

[0029] Before the strands 28 cool, harden, and cure into a nonwoven web cushion material, the tooling plate 62 induces a shape on the cushion 22. The secondary forming process for creating the shape, contour, seat surface, and connection surface can be eliminated. The cushion 60 is cut from the continuously formed web assembly 46. Alternatively, the cushion 22 can be formed from multiple web assembly segments 60 having an overall contour with sequential transitions, which are combined within the decorative cover 26. These segments 60 can be glued, welded, or otherwise fastened together.

[0030] The tooling plate 62 can have varying angles along different surfaces of the leading edge 66 to obtain the desired material resistance. The tooling plate 62 can be formed by rapid manufacturing processes, such as by machining, three-dimensional printing, etc. The tooling plate 62 can be machined from a metal alloy or a polymer material. Similarly, the tooling plate 62 can be printed from a polymer material.

[0031] Although multiple 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. Additionally, the features of the various embodiments can be combined to form additional embodiments according to the present disclosure.

Claims

1. A product including a body having a non-rectangular cross-section, the body being formed by multiple strands of expanded thermoplastic resin, wherein, The density of the plurality of strands around the perimeter of the non-rectangular cross-section is greater than the density within the perimeter to provide a contact surface around the perimeter.

2. The product according to claim 1, wherein, The plurality of strands around the perimeter of the non-rectangular cross-section with a density greater than the density within the perimeter are further defined as multiple rows of strands.

3. The product according to claim 1 or claim 2, wherein, The body is sized to provide a cushion.

4. A seat assembly, comprising: A seat frame; And The cushion according to claim 3.

5. A method of manufacturing a product, comprising: Dispensing outer plurality of strands of molten thermoplastic resin through a tool having an orifice to join a leading edge and then through the orifice, and dispensing inner plurality of strands of the molten thermoplastic resin to pass through the orifice without joining the leading edge, the size of the orifice matching the entire cross-section of the product; and Impeding the flow of the plurality of strands while cooling the plurality of strands, the impeding providing a one-piece nonwoven body in the shape of the entire perimeter of the product, the one-piece nonwoven body having an increased density of the strands along the perimeter of the cross-section of the product as compared to the density of the strands contained within the perimeter.

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

7. The method according to claim 5 or claim 6, wherein, The product is further defined as a cushion.

8. The method according to claim 5 or claim 6, further comprising: Dispensing the molten thermoplastic resin with an array of nozzles having an area greater than the area of the orifice such that the molten thermoplastic resin joins the leading edge.

9. The method according to claim 8, further comprising: Dispensing the molten thermoplastic resin with an array of nozzles having an area greater than the area of the orifice, up to three rows of nozzles within the array having an area greater than the area of the orifice.

10. The method according to claim 5 or claim 6, further comprising: Lubricating the leading edge before and / or during dispensing of the molten thermoplastic resin.

11. The method according to claim 10, further comprising: Lubricating the leading edge with water.

12. The method according to claim 5 or claim 6, further comprising: Lubricating a fabric disposed along the leading edge before and / or during dispensing of the molten thermoplastic resin.

13. A product formed by the method according to claim 5 or claim 6.

14. The product according to claim 13, further comprising a seat cushion.

15. The method according to claim 5 or claim 6, further comprising: Mounting the body as a cushion to a seat assembly.

16. A seat assembly, the seat assembly being manufactured by the method according to claim 15.

17. The method according to claim 5 or claim 6, further comprising machining the tool body.

18. The method according to claim 5 or claim 6, further comprising forming the tool from a metal alloy.

19. The method according to claim 5 or claim 6, further comprising three-dimensional printing the tool.

20. The method according to claim 5 or claim 6 further comprises forming the tool from a polymeric material.

21. A tool includes a tool body having a through-orifice and a leading edge surrounding the orifice, the through-orifice being sized to match an entire periphery of a product, the leading edge and the through-orifice being sized to receive molten thermoplastic resin as a plurality of dispensed strands, wherein, The through-hole of the tool is sized to hold the plurality of dispensed strands within the entire perimeter of the product.

22. The tool according to claim 21, wherein, The through-hole of the tool is non-rectangular to form the product having a non-rectangular cross-section.

23. The tool according to claim 21 or claim 22, wherein, The through-hole of the tool is sized to conform to the cross-section of a seat cushion.

24. The tool according to claim 21 or claim 22, wherein The tool body further comprises a plate.

25. An assembly comprising the tool according to claim 21 or claim 22, further comprising a fabric mounted on the tool.

26. A system comprising: An extruder for a thermoplastic resin ； The tool according to claim 21 or claim 22, the tool being aligned to receive the dispensed thermoplastic resin from the extruder; and A fluid chamber oriented below the tool to receive the dispensed thermoplastic from the tool to cool the thermoplastic resin into a product.

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