Cushion assembly

Abstract

The invention relates to a cushion assembly. A gasket is provided with a wire mesh member and a fastener strip. A wire mesh member is provided with a set of filaments of thermoplastic material, wherein each member of the set is bonded to at least one other member of the set. The fastener strip is welded to the wire mesh member. An aperture is formed in a first surface of the wire mesh member spaced apart from the fastener strip.

Description

Technical Field

[0001] Various embodiments relate to a gasket assembly and a method of manufacturing a gasket. Brief description of the attached diagram

[0002] Figure 1 This is a perspective view of an example of a seat assembly that includes a filament mesh structure.

[0003] Figure 2 This is a schematic diagram of an example manufacturing system used to create wire mesh structures.

[0004] Figure 3 yes Figure 1 A perspective view of the cushioning of the seat assembly.

[0005] Figure 4 yes Figure 3 Another perspective view of the padding.

[0006] Figure 5 yes Figure 1 A bottom view of the trim cover of the seat assembly.

[0007] Figure 6 It works in conjunction with cutting tools. Figure 1 A perspective view of the seat assembly padding, showing a step of the manufacturing method according to an embodiment.

[0008] Figure 7 yes Figure 6 A perspective view showing the collaboration between the liner and welding tools illustrates another step in the manufacturing process.

[0009] Figure 8 yes Figure 6 padding and Figure 7 A perspective view of the welding tools working together shows another step in the manufacturing process.

[0010] Figure 9 yes Figure 6 padding and Figure 7 A perspective view of the welding tools working together shows another step in the manufacturing process. Detailed description

[0011] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. Numerous specific details are set forth in the following detailed description in order to provide a thorough understanding of the various embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described can be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0012] It should be understood that the disclosed embodiments are merely exemplary, and 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. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to implement the embodiments according to this disclosure in various ways.

[0013] "One or more" includes functions performed by one element, functions performed by more than one element (e.g., in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0014] It should also be understood that although the terms first, second, etc., are used in some instances herein to describe various elements, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first fastener may be referred to as a second fastener, and similarly, a second fastener may be referred to as a first fastener, without departing from the scope of the various embodiments described. Both the first fastener and the second fastener are fasteners, but they are not the same fastener.

[0015] The terminology used in the description of the various embodiments described herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various 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 covers any and all possible combinations of one or more of the listed related 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 stated features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof.

[0016] As used herein, the term "if" may optionally be interpreted as "when," "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" may optionally be interpreted as "when determined," "in response to determining," "when [the condition or event] is detected," or "in response to detecting [the condition or event]," depending on the context.

[0017] A liner is disclosed, comprising a wire mesh component and a fastener band, the wire mesh component comprising a set of filaments of thermoplastic material, wherein each component or filament of the set of filaments is looped and bonded to at least one other component or filament of the set of filaments; the fastener band is welded to the wire mesh component.

[0018] In one or more examples, the fastener band includes hook fasteners and / or ring fasteners.

[0019] In one or more examples, the fastener band also includes hook fasteners.

[0020] In one or more examples, the fastener band is further defined as a first fastener band. The gasket may also include a second fastener band fastened to the first fastener band.

[0021] In one or more examples, the second fastener band also includes a loop fastener band.

[0022] In one or more examples, the liner also includes a decorative element attached to the second fastener band.

[0023] In one or more examples, the decorative component also includes a decorative cover that is at least partially disposed above the exterior of the wire mesh component.

[0024] In one or more examples, the fastener band and the wire mesh component each comprise similar recyclable materials.

[0025] In one or more examples, the opening is formed in a first surface of the wire mesh component, optionally spaced apart from the fastener band.

[0026] A seat assembly is disclosed, comprising a seat frame and a padding as defined above attached to the frame. The padding may include a wire mesh component and a fastener band, the wire mesh component comprising a set of filaments of a thermoplastic material, wherein each component or filament of the set of filaments is looped and bonded to at least one other component or filament of the set of filaments; the fastener band is welded to the wire mesh component.

[0027] In one or more examples, the fastener band is further defined as a first fastener band. The padding may also include a second fastener band fastened to the first fastener band. The seat assembly may also include a trim member attached to the second fastener band. The trim member may also include a trim cover disposed at least partially above the exterior of the wire mesh member. The trim cover may at least partially cover the seat frame.

[0028] A liner is disclosed, comprising a wire mesh component and a support member. The wire mesh component comprises a set of filaments of a thermoplastic material, wherein each component or filament in the set of filaments is looped and bonded to at least one other component or filament in the set of filaments, wherein openings are formed in a first surface of the wire mesh component; the support member is welded to the wire mesh component at a second surface spaced apart from the first surface.

[0029] In one or more examples, the orifice is formed as a blind depth.

[0030] In one or more examples, the blind depth is spaced apart from the support.

[0031] In one or more examples, the orifice is formed as a slit.

[0032] In one or more examples, the orifice is sealed.

[0033] A method is disclosed comprising forming a wire mesh component comprising a set of filaments of a thermoplastic material, wherein each component or filament in the set of filaments is looped and bonded to at least one other component or filament in the set of filaments, wherein orifices are formed in a first surface of the wire mesh component; inserting a welding tool into the orifices of the wire mesh component; and welding a region of the wire mesh component.

[0034] In one or more examples, the method also includes welding the support to the area of ​​the wire mesh component.

[0035] In one or more examples, the method also includes retracting the welding tool after welding the wire mesh component.

[0036] A seat liner is disclosed, which is formed by the method described above. The method may include forming a wire mesh component comprising a set of filaments of a thermoplastic material, wherein each component or filament in the set of filaments is looped and bonded to at least one other component or filament in the set of filaments, wherein orifices are formed in a first surface of the wire mesh component; inserting a welding tool into the orifices of the wire mesh component; and welding a region of the wire mesh component.

[0037] refer to Figure 1An example of seat assembly 10 is shown. In some embodiments, seat assembly 10 is a vehicle seat assembly, such as for land vehicles (e.g., cars, trucks, buses, etc.) or for non-land vehicles (e.g., aircraft or boats). For example, seat assembly 10 for land vehicles may be shaped and sized for use as a front driver or passenger seat, a second, third, or other rear seat, and may include bucket seats, bench seats, or other seat styles. Furthermore, seat assembly 10 may be a non-retractable seat or a retractable seat; retractable seats may be foldable and can be stored in cavities within the vehicle floor. Additionally, seat assembly 10 may be configured for non-vehicle applications, such as furniture.

[0038] exist Figure 1 In the configuration shown, seat assembly 10 includes a seat base 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when seat assembly 10 is configured as a motorcycle seat or stool.

[0039] The seat base 20 is configured to receive a seated occupant and support the occupant's pelvis and thighs. The seat base 20 includes a seat base frame 30, a cushion 32, and a decorative cover 34.

[0040] The seat bottom frame 30 is a structure that supports the padding 32. The seat bottom frame 30 includes one or more structural members and can be made of any suitable material, such as metal alloys, polymer materials, fiber-reinforced polymer materials, or combinations thereof. In some configurations, the seat bottom frame 30 includes a panel on which the padding 32 is disposed, a seat pan, a suspension pad, or suspension wire.

[0041] A cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a deformable material that supports the seat occupant and distributes the load force from the seat occupant to the seat bottom frame 30. The cushion 32 and related manufacturing methods will be discussed in more detail below.

[0042] The decorative cover 34 covers at least a portion of the padding 32. Additionally, the decorative cover 34 provides one or more visible outer surfaces of the seat back 22. When seated in the seat assembly 10, the seat occupant can rest on the decorative cover 34. The decorative cover 34 is made of any suitable material or a combination thereof (e.g., fabric, leather, artificial leather, vinyl, or combinations thereof). The decorative cover 34 may include multiple decorative panels assembled in any suitable manner (e.g., by fusion or stitching). The decorative cover 34 is attached to the seat bottom frame 30, the padding 32, or both. For example, the decorative cover 34 may include decorative attachment features attached to the seat bottom frame 30, the padding 32, or both to prevent removal of the decorative cover 34 and to help the decorative cover 34 conform to the shape of the seat bottom frame 30, the padding 32, or both. The decorative cover 34 may also be attached to an attachment base plate, which will be discussed in more detail below.

[0043] The seat backrest 22 is configured to support the back of a seated occupant. The seat backrest 22 is disposed adjacent to the seat bottom 20. For example, the seat backrest 22 may be positioned above and near the rear of the seat bottom 20. The seat backrest 22 extends in a generally upward direction away from the seat bottom 20. In some configurations, the seat backrest 22 is mounted to the seat bottom 20 and can pivot relative to it. In other configurations, the seat backrest 22 is not mounted to the seat bottom 20. For example, a vehicle seat backrest may be mounted to the vehicle body structure, such as in some second-row seat assemblies. The seat backrest 22 includes a seat backrest frame 40, a pad 42, a trim cover 44, and an optional headrest 46.

[0044] 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 metal alloys, polymer materials, fiber-reinforced polymer materials, or combinations thereof. In some configurations, the seat back frame 40 includes a panel, base plate, suspension pad, or suspension wires on which the cushion 42 is disposed. It is also conceivable that in some configurations, the seat back frame 40 may be integrally formed with the seat bottom frame 30.

[0045] A pad 42 is disposed on the seat back frame 40. The pad 42 is made of a deformable material that supports the seat occupant and distributes the load force from the seat occupant to the seat back frame 40. It is conceivable that the pad 42 may be integrally formed with the pad 32 of the seat bottom 20, or may be separate from the pad 32 of the seat bottom 20. The pad 42 and related manufacturing methods will be discussed in more detail below.

[0046] The decorative cover 44 covers at least a portion of the padding 42. Additionally, the decorative cover 44 provides one or more visible outer surfaces of the seat back 22. When seated in the seat assembly 10, the seat occupant can rest on the decorative cover 44. The decorative cover 44 is made of any suitable material or a combination thereof (e.g., fabric, leather, artificial leather, vinyl, or combinations thereof). The decorative cover 44 may include one or more decorative panels assembled in any suitable manner (e.g., by fusion or stitching). The decorative cover 44 is attached to the seat back frame 40, the padding 42, or both. For example, the decorative cover 44 may include decorative attachment features attached to the seat back frame 40, the padding 42, or both to prevent removal of the decorative cover 44 and to help the decorative cover 44 conform to the shape of the seat back frame 40, the padding 42, or both. The decorative cover 44 may also be attached to an attachment base plate, which will be discussed in more detail below.

[0047] A headrest 46 (if provided) is configured to support the head of the seat occupant. The headrest 46 is located at the top of the seat back 22, or at one end of the seat back 22 opposite to the seat bottom 20. The headrest 46 can be movable relative to the seat back 22 in one or more directions, or it can be integrally formed with the seat back 22.

[0048] refer to Figure 3 and Figure 4 An example of pad 50 is shown. For ease of reference, pads are generally designated by reference numeral 50. It should be understood that the structure and description of pad 50 apply to pad 32 of seat bottom 20, pad 42 of seat back 22, or both.

[0049] The pad 50 is a non-foam component or includes at least one non-foam component. The non-foam component is primarily referred to as a mesh component, but may also be referred to as a wire component, looped component, entangled component, wire mesh structure, mesh structure, wire mesh, looped mesh, entangled mesh, or mesh pad. Figure 3 and Figure 4 In this context, cushion 50 is described as a non-foam component that does not include foam components or foam materials (such as urethane or polyurethane foam); however, it is conceivable that cushion 50 may include foam components or foam materials in addition to non-foam components to provide additional or localized cushioning for seat occupants. For example, foam material may be disposed between cushion 50 and a trim cover (e.g., trim cover 34, 44), on cushion 50, within cushion 50, or in a combination thereof. Reducing the amount of foam material provided to cushion 50 or removing foam material from cushion 50 can reduce weight and improve support and comfort for seat occupants. Furthermore, removing foam material can facilitate the recycling of cushion 50.

[0050] The liner 50 is described below without the foam material. In this case, the liner 50 is made of filaments 52 of polymer material, which are randomly looped, bent, curled, or tangled and bonded together, as will be discussed in more detail below. The filaments 52 are bonded directly to one another, rather than indirectly bonded with resin or other intermediate materials.

[0051] The filament 52, also referred to as a strand or thread, is made of any suitable material or a combination of materials. In some configurations, the filament 52 is made of a polymeric or thermoplastic material, such as a polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based, or combinations thereof thermoplastic resins. As an example, a polyethylene-based filament can be made of linear low-density polyethylene (LLPDE). Unlike foam materials, the filament material can be recyclable or more easily recyclable than foam materials. It is also conceivable that the filament 52 may include reinforcing fibers, and the reinforcing fibers may not be made of thermoplastic materials.

[0052] In some configurations, filament 52 may be a monofilament made of a single material. In some configurations, filament 52 may be made of multiple materials. For example, filament 52 made of multiple materials may include a core made of a first thermoplastic material and a sheath surrounding the core and made of a second thermoplastic material different from the first thermoplastic material. It is envisioned that pad 50 may include a combination of monofilaments and filaments, where the filaments are made of multiple materials and are not monofilaments.

[0053] Randomly looped, bent, curled, or tangled filaments 52 are joined 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 (with openings or gaps between filaments 52). Figure 2 An example of a manufacturing system 60 for manufacturing gaskets or wire mesh structures is also shown. In this example, manufacturing system 60 includes a material feeder 70, an extruder 72, and a funnel 74. Manufacturing system 60 also includes a cooling tank 76 and a material transfer subsystem 78.

[0054] refer to Figure 2 The material feeder 70 holds the material raw material to be extruded, such as solid beads, flakes, granules, pellets, or powder made from the material. In some configurations, the material feeder 70 is configured as a container or hopper. The material feeder 70 supplies the material raw material to the extruder 72.

[0055] Extruder 72 melts the material feedstock and extrudes it into a set of filaments 52. Extruder 72 can have any suitable configuration. In some configurations, extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material to move through the barrel, and the friction generated by the screw's rotation helps to heat the material. The material exits the barrel under pressure and in a molten state, and is conveyed under pressure to the die 80 of extruder 72.

[0056] The die 80 (also called a die plate or extrusion die) has multiple through holes or filament-forming openings through which molten material passes. A single filament 52 is extruded from each through hole. Under the influence of gravity, the filament 52 falls from the die 80 into the funnel 74.

[0057] The funnel 74 combines or separates the filaments 52 into a more compact arrangement, wherein the filaments are bent, curled, or looped, and the filaments 52 contact and bond to at least one other filament 52. The funnel 74 has an inlet opening or funnel inlet and an outlet opening or funnel outlet smaller than the funnel inlet. Individually separated filaments 52 enter the funnel inlet. As the filaments 52 accumulate, they bend, curl, or loop and move into contact. As the filaments 52 move toward the funnel outlet, they move through the funnel 74 or an intermediate plate disposed on the funnel 74. Bonds are formed between the filaments 52 at the contact points, while openings or gaps exist between the filaments 52 at other locations where one filament 52 does not contact or bond to another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter the cooling tank 76. For ease of reference, the bonded filaments 52 are referred to as a mesh member or wire mesh structure 90.

[0058] Cooling tank 76 contains a liquid, such as water or a mixture of water and another fluid. The liquid in cooling tank 76 helps support the tangled and bonded filaments 52, limiting further compaction or solidification of the filaments 52 into an arrangement with fewer openings or orifices, and maintaining the desired porosity and density of the mesh structure 90. Thus, the liquid provides some buoyancy or resistance that can cause additional bending, curling, or looping of the filaments 52 adjacent to the liquid surface or within funnel 74 to further construct the mesh structure 90. While the filaments 52 are in the liquid, the liquid also cools the filaments 52. For example, the liquid cools the filaments 52 from the outside to solidify them and prevent them from bonding in additional locations. At this point, the filaments 52 are relatively rigid and no longer in a plastic state, thus generally retaining their shape and not plasticizing or reshaping without reheating.

[0059] The material transfer subsystem 78 conveys the wire mesh structure 90 through the cooling tank 76. The material transfer subsystem 78 includes various rollers and conveyors that facilitate the movement of the wire mesh structure 90 through and out of the liquid. In some configurations, a traction conveyor 92 is positioned within the cooling tank 76 to assist in pulling the wire mesh structure 90 out of the funnel 74 and counteracting the buoyancy of the wires 52.

[0060] One or more other rollers (e.g., roller 94) keep the wire mesh structure 90 submerged in the liquid and guide it through the cooling tank 76. For example, roller 94 may guide the wire mesh structure 90 toward a conveyor belt 96 and a shaker table 98 disposed outside the cooling tank 76. While the wire mesh structure 90 is on the conveyor belt 96, the shaker table 98 shakes the wire mesh structure 90 to remove liquid. Alternatively or additionally, the filamentous mesh structure 90 may be squeezed to remove liquid, air may be blown onto the filamentous mesh structure 90 to aid in the removal of liquid, or both. It is also conceivable that the wire mesh structure 90 may be allowed to air dry or be dried in ambient air.

[0061] The aforementioned manufacturing system 60 is a continuous flow process, in which the wire mesh structure 90 is formed as a continuous structure while the filament extrusion is uninterrupted. After exiting the cooling tank 76, further processing of the wire mesh structure 90 is provided to cut it into individual pieces or blanks for individual pads. This processing is performed by a cutting subsystem of the manufacturing system 60. The cutting subsystem can be of any suitable type. For example, the cutting subsystem can use blades, knives, hot knives, saws, fluid jets, etc., to cut the filaments 52 of the wire mesh structure 90 into blanks. The cutting subsystem can be used to shape or contour the blanks. It is also envisioned that the blanks can be further shaped or contoured using other manufacturing processes, such as molding the entire blank or a portion thereof.

[0062] Using the above process, the pad 50 can be formed from a set of filaments 52, wherein at least two members of the set of filaments 52 are looped and bonded to each other. In one or more embodiments, each member of the set of filaments 52 is looped and bonded to at least one other member of the set of filaments 52.

[0063] Refer again Figure 3 and Figure 4An example of a pad 50 is shown, provided by a portion 50 or blank 50 of a mesh structure 90 including filaments 52. A support, such as a fastener band 120, contacts and attaches to the pad 50. In some embodiments, the fastener band 120 is a hook fastener band. One hook fastener band includes a fabric band having a plurality of polymer hooks. In other configurations, the fastener band 120 is a loop fastener band. A loop fastener band includes a fabric band having a plurality of polymer loops. When the hook band fabric is pressed against the loop band fabric, the hooks engage with the loops, forming a strong bond that can be separated upon peeling.

[0064] In other embodiments, the fastener band 120 may take the form of an alternative fastener, such as a band, which may vary depending on the material or fabric, and may include clips, longitudinal fasteners, zippers, rope inserts, flex hook fasteners, dual prong fasteners, peg fasteners, and a series of such fasteners.

[0065] Fastener band 120 provides the first fastener in the fastener assembly. Figure 5 A decorative element 122 according to another embodiment is shown. According to some embodiments, the decorative element 122 is a decorative cover, such as a decorative cover 34 or a decorative cover 44. According to other embodiments, the decorative element 122 is an actuator, such as a bladder assembly, a heat transfer assembly, a heated base plate, or any other suitable decorative element that can be attached to the pad 50.

[0066] A second fastener band 124 is attached to the underside of the trim member 122, wherein the second fastener band 124 will be concealed during assembly. The second fastener band 124 cooperates with the first fastener band 120 to attach the trim member 122 to the pad 50. The second fastener band 124 is attached to the trim member 122 by any suitable fastener, such as welding, stitching, adhesive, coextrusion, insert molding, etc. In embodiments where the trim member 122 is a trim cover 122, the second fastener band 124 allows the trim cover 122 to be seamlessly attached to the pad 50 without any externally visible seam. Proper fastening along the concave pad surface is allowed without the need for grooves within the pad 50. By utilizing longitudinal band fasteners 120, 124, adhesives that could otherwise generate audible noise associated with occupant seating and removal during load application and withdrawal can be eliminated.

[0067] According to one embodiment, the liner 50 and the first fastener band 120 each comprise similar recyclable materials, such as thermoplastic resins based on polyamide, polyester, polyimide, polyolefin, polypropylene, polyethylene, polystyrene, or combinations thereof; as an example, the polyethylene-based wire mesh component can be made of linear low-density polyethylene (LLPDE). Similar materials eliminate the need for adhesives and allow for the recycling of similar materials. Similarly, the second fastener band 124 can be formed from similar recyclable materials. Furthermore, the decorative component 122 can also be formed from similar recyclable materials.

[0068] Refer again Figure 3 and Figure 4 The gasket 50 and the first fastener band 120 are at least partially joined together along the mating surfaces 126, 128 between the gasket 50 and the first fastener band 120. A plurality of weld portions 130 are formed at least partially along the mating surfaces 126, 128 of the gasket 50 and the first fastener band 120. The weld portions 130 may be formed at least partially through the gasket 50, such as... Figure 4 As shown.

[0069] The weld 130 between the gasket 50 and the first fastener band 120 results in a strong and uniform bond. In the configuration of the first fastener band 120 as one of a hook fastener band and a ring fastener band, sufficient fastener band material is retained around the weld 130, making it easy for the hook material to bond to the ring material.

[0070] refer to Figure 6 The gasket 50 and the fastener band 120 are stacked on top of each other. The mating surfaces 126 and 128 of the gasket 50 and the fastener band 120 contact each other. A cutting tool 132 is used to form an orifice 134 in the gasket 50. The cutting tool 132 is schematically shown as a pair of scissors. However, the cutting tool 132 can be any suitable type, such as a blade, knife, hot knife, saw, fluid jet, etc. The cutting tool 132 can be provided in the cutting subsystem of the manufacturing system 60. Alternatively, the cutting tool 132 can be provided downstream in a subsequent or separate manufacturing operation.

[0071] exist Figure 6 In this configuration, the orifice 134 is formed as a slit 134 passing through the base surface 136 of the gasket 50, spaced apart from the mating surface 126. The slit 134 is formed as a blind depth 138 spaced apart from the mating surface 126. The distance from the blind depth 138 to the mating surface is a dimension suitable for performing welding operations on the gasket 50 and the first fastener band 120. Additionally, the slit 134 is sized to receive a portion of the welding tool 140 for performing the welding operation.

[0072] Figure 7A pad 50 is shown stacked on the first fastener band 120. The pad 50 and the first fastener band 120 are presented below a welding tool 140. The welding tool 140 can be operated automatically or manually. According to one embodiment, the welding tool 140 is an ultrasonic welding tool 140. Any welding tool 140 can be used, such as a heating welder or a friction stir welder. The welding tool 140 includes a welding arm 142 and has a welding end 144 at the distal end of the welding arm 142.

[0073] exist Figure 8 In this embodiment, the welding arm 142 extends a welding tip 144 into a slit 134 in the base surface 136 to contact the blind depth 138 of the gasket 50. According to an embodiment, the welding tip 144 can be used to compress a portion of the gasket 50 to enhance contact between the gasket 50 and the first fastener band 120. The welding tip 144 also ultrasonically vibrates under the pressure of the welding arm 142 to generate friction between the gasket 50 and the first fastener band 120, melting the gasket 50 and the first fastener band 120 at mating surfaces 126, 128.

[0074] exist Figure 9 In the process, the molten mating surfaces 126, 128 of the gasket 50 and the first fastener band 120 cool to solidify and form a weld 130. The welding arm 142 retracts to allow the gasket 50 to expand as it is welded. The weld 130 includes a consistent depth, for example, a certain number of strands 52 extending beyond the mating surfaces 128. In some examples, the number of strands 52 can be as high as three strands 52 or two millimeters. The consistent depth of the weld 130 is more repeatable than adhesive, which typically drips beyond the mating surfaces and produces a denser and inconsistent bond beyond the lower mating surface. By omitting the adhesive, the gasket 50 is formed from a consistent material, thus simplifying recyclability. Additionally, the weld 130 provides flexibility that is less rigid compared to comparable adhesive bonds.

[0075] The welded pad 50 provides a lightweight, sustainable comfort solution for the seat assembly 10, thereby reducing vehicle weight while maintaining occupant support, thus lowering costs and improving fuel efficiency. The strands 52 of the pad 50 provide a reduced surface area for bonding. However, compression and / or welding of the pad 50 enhances the density and area of ​​the mating surfaces 126 to create a weld 62 that is stronger than the adhesive in applicable tests (e.g., shear resistance). Although a pad 50 and a fastener band 120 are shown welded together, various pads 50 can be manufactured using any number of pads 50 or pad sections or segments 50, as well as fastener bands 120 and any number of welds 130.

[0076] According to another embodiment, the orifice 134 can be sealed by welding, adhesive, or the like. The sealed orifice 134 can be used to return the gasket 50 to a position similar to... Figure 6 The solid configuration of the configuration prior to the cutting operation.

[0077] Various parameters of the welding process can be modified for different specifications or applications. For example, the power, voltage, and current of the welding tool 140 can be adjusted to regulate the performance of the weld section 130. Similarly, the performance of the weld section 130 can be altered by adjusting the proximity of the contact point between the welding tip 144 and the backing 50, as well as the pressure applied to the backing 50 by the extension of the welding arm 142. The performance can also be modified by changing the duration of the weld section 130. At the welding tip 144, the frequency of the tip 144 can be changed for different welding performances. Additionally, the shape of the welding tip 144 can be adjusted to regulate performance resulting in surface welding, spot welding, etc.

[0078] Different mating configurations can be achieved using various configurations of the gasket mating surface 126. For example, the gasket mating surface 126 may include a surface layer. Furthermore, the weld portion 130 can be modified by changing the material of the gasket 50, adjusting the area of ​​the mating surfaces 126 and 128, or changing the number of weld portions 130. Various materials may include polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, polycarbonate, thermoplastic polyester elastomer, acrylonitrile butadiene styrene, polyoxymethylene, etc.

[0079] According to the first clause, either alone or in combination with any of the preceding clauses, the liner is provided with a wire mesh component comprising a set of filaments of thermoplastic material, wherein each component of the set of filaments is looped and coupled to at least one other component of the set of filaments. Fasteners are welded to the wire mesh component.

[0080] According to the second clause, a gasket is provided in accordance with any one of the foregoing or successive clauses, wherein the fasteners include hook fasteners or ring fasteners.

[0081] According to the third clause, a gasket is provided in accordance with any one of the foregoing or successive clauses, wherein the fasteners further include hook fasteners.

[0082] According to the fourth clause, a gasket is provided according to any one of the foregoing or successive clauses, wherein the fastener is further defined as a first fastener, and wherein the gasket is further provided with a second fastener fastened to the first fastener.

[0083] According to Clause 5, a gasket is provided according to any one of the foregoing or successive clauses, wherein the second fastener further includes a ring fastener.

[0084] According to Clause 6, the liner described in any of the preceding or successive clauses is provided with a decorative component attached to the second fastener.

[0085] According to Clause 7, the padding described in any of the preceding or successive clauses is provided with a decorative cover, which is at least partially disposed above the exterior of the wire mesh component.

[0086] According to Article 8, a liner is provided in accordance with any of the foregoing or successive articles, wherein the fasteners and wire mesh components each comprise similar recyclable materials.

[0087] According to Article 9, a gasket is provided according to any one of the foregoing or successive articles, wherein orifices are formed in a first surface of the wire mesh member spaced apart from the fasteners.

[0088] According to Article 10, a seat assembly is provided with a seat frame and is provided with padding attached to the frame for any of the foregoing or successive articles.

[0089] According to Clause 11, a seat assembly as described in the foregoing clause is also provided, wherein the fastener band is further defined as a first fastener. The cushion is also provided with a second fastener fastened to the first fastener. The seat assembly is also provided with a decorative element attached to the second fastener. The decorative element is further provided with a decorative cover, which is at least partially disposed above the exterior of the mesh member. The decorative cover at least partially covers the seat frame.

[0090] According to Clause Twelve, a liner is provided, either alone or in combination with any of the foregoing or successive clauses. A wire mesh component is provided with a set of filaments of thermoplastic material, wherein each component of the set of filaments is looped and coupled to at least one other component of the set of filaments, wherein openings are formed in a first surface of the wire mesh component; a support is welded to the wire mesh component at a second surface spaced apart from the first surface.

[0091] According to Article XIII, a gasket is provided pursuant to any of the foregoing or successive articles, wherein the orifice is formed to a blind depth.

[0092] According to Article 14, a liner is provided pursuant to any of the foregoing or successive articles, wherein the blind depth is spaced apart from the support.

[0093] According to Article 15, a gasket is provided pursuant to any of the foregoing or successive articles, wherein the orifice is formed as a slit.

[0094] Pursuant to Article 16, a gasket pursuant to any one of the preceding articles is provided, wherein the orifice is sealed.

[0095] Pursuant to Article 17, a method is provided, alone or in combination with any successive articles, comprising forming a wire mesh component from a set of thermoplastic filaments, wherein each component of the set of filaments is looped and bonded to at least one other component of the set of filaments, wherein openings are formed in a first surface of the wire mesh component. A welding tool is inserted into the openings of the wire mesh component. Areas of the wire mesh component are welded.

[0096] According to Article 18, the method of any of the foregoing or successive articles includes the following steps: welding the support to the area of ​​the wire mesh component.

[0097] According to Article 19, the method of any of the preceding or successive articles includes the following steps: retracting the welding tool after welding the wire mesh component.

[0098] According to Article 20, a seat cushion is formed by any of the methods described in the preceding articles.

[0099] While various embodiments have been described above, this does not mean that these embodiments describe all possible forms according to this disclosure. In this regard, the terminology used in the specification is descriptive rather than limiting, and it should be understood that various changes can be made without departing from the spirit and scope of this disclosure. Furthermore, features of embodiments implemented with various parameters can be combined to form other embodiments according to this disclosure.

Claims

1. A padding comprising: A wire mesh component comprising a set of filaments of a thermoplastic material, wherein each component of the set of filaments is looped and coupled to at least one other component of the set of filaments; and Fastener band, which is welded to the wire mesh component.

2. The gasket according to claim 1, wherein, The fastener band includes hook fasteners or ring fasteners.

3. The gasket according to any one of claims 1-2, wherein, The fastener band also includes hook fasteners.

4. The gasket according to any one of claims 1-3, wherein, The fastener band is further defined as a first fastener band, and The gasket also includes a second fastener band that is fastened to the first fastener band.

5. The gasket according to claim 4, wherein, The second fastener band also includes a ring fastener band.

6. The gasket according to any one of claims 4-5, further comprising a decorative component attached to the second fastener strip.

7. The gasket according to claim 6, wherein, The decorative component also includes a decorative cover, which is at least partially disposed above the outside of the wire mesh component.

8. The gasket according to any one of claims 1-7, wherein, The fastener band and the wire mesh component each comprise similar recyclable materials.

9. The gasket according to any one of claims 1-8, wherein, The opening is formed in the first surface of the wire mesh component, which is spaced apart from the fastener band.

10. A seat assembly, comprising: Seat frame; as well as The padding according to any one of claims 1-9 is attached to the frame.

11. The seat assembly of claim 10, wherein, The fastener band is further defined as a first fastener band; The gasket further includes a second fastener band that is fastened to the first fastener band; The seat assembly also includes a decorative component attached to the second fastener strap; The decorative component further includes a decorative cover, which is at least partially disposed above the outside of the wire mesh component; and The decorative cover at least partially covers the seat frame.

12. A padding comprising: A wire mesh component comprising a set of filaments of a thermoplastic material, wherein each component of the set of filaments is looped and coupled to at least one other component of the set of filaments, wherein openings are formed in a first surface of the wire mesh component; and A support member, which is welded to the wire mesh component at a second surface spaced apart from the first surface.

13. The gasket according to claim 12, wherein, The orifice is formed to a blind depth.

14. The gasket according to claim 13, wherein, The blind depth is spaced apart from the support member.

15. The gasket according to any one of claims 12-14, wherein, The opening is formed as a slit.

16. The gasket according to any one of claims 12-15, wherein, The orifice was sealed.

17. A method comprising: A wire mesh component is formed, the wire mesh component comprising a set of filaments of thermoplastic material, wherein each component of the set of filaments is looped and coupled to at least one other component of the set of filaments, wherein openings are formed in a first surface of the wire mesh component; and Insert the welding tool into the opening of the wire mesh component; and The area where the wire mesh component is welded.

18. The method of claim 17, further comprising welding a support to the region of the wire mesh component.

19. The method according to any one of claims 17-18, further comprising retracting the welding tool after welding the wire mesh component.

20. A seat cushion formed by the method of any one of claims 17-19.

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