System and method for producing a tissue structure

Abstract

A system and method for producing a filament fabric structure. The filament fabric structure is placed in a cavity of a mold assembly. Liquid above a first temperature threshold is added to the cavity, softening the filament fabric structure and allowing it to conform to a forming surface of the mold assembly. The filament fabric structure is then cooled within the mold assembly to set the shape.

Description

Cross-reference to related applications

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 510,793, filed June 28, 2023, the disclosure of which is hereby incorporated by reference in its entirety. Technical area

[0002] Various embodiments relate to a system and method for forming a fabric structure, such as a pillow. Short description of the drawings Fig. 1 is a perspective view of an example of a seat assembly incorporating a filament fabric structure. Fig. 2 is a perspective view of an example of a cushion of the seat assembly made of a filament fabric structure. Fig. 3 is a schematic diagram of an example of a manufacturing system for producing the filament fabric structure. Fig. 4 is an exploded view of an example of a mold assembly and the filament fabric structure before it is formed in the mold assembly. Fig. 5 is a flowchart of an example of a method for forming the filament fabric structure. The Fig. 6 and Fig. 7 show a first example of adding liquid into a cavity of the mold assembly according to the method. The Fig. 8 and Fig. 9 show a second example of adding liquid into a cavity of the mold assembly according to the method. The Fig. 10 and Fig. 11 show a third example of adding liquid into a cavity of the mold assembly according to the method. The Fig. 12 and Fig. 13 show a first example of cooling the filament fabric structure according to the method. The Fig. 14 and Fig. 15 show a second example of cooling the filament fabric structure according to the method. The Fig. 16 and Fig. 17 show a third example of cooling the filament fabric structure according to the method. The Fig. 18 and Fig. 19 show a fourth example of cooling the filament fabric structure according to the method. Detailed description

[0003] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for showing one skilled in the art how to variously employ the present invention.

[0004] Reference will now be made in detail to 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 skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, operations, components, circuits, and networks have not been described in detail in order 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 figures are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art how to variously employ embodiments in accordance with the disclosure.

[0006] “One or more” includes a function performed by one element, a function performed by more than one element, such as in a distributed form, multiple functions performed by one element, multiple functions performed by multiple elements, or any combination of the above.

[0007] It should also be understood that although the terms "first," "second," etc., are used herein in some instances 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 contact could be referred to as a second contact, and similarly, a second contact could be referred to as a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0008] 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," "the," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It is also to be understood that the term "and / or," as used herein, refers to and includes all possible combinations of one or more of the listed items.Furthermore, the terms "includes", "containing", "comprises" and / or "comprising", when used in this specification, are understood to specify the presence of the specified 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" may be interpreted as "when" or "upon" or "in response to the determination" or "in response to the detection," depending on the context. Similarly, the phrase "when it is determined" or "when [a specified condition or event] is detected" may be interpreted to mean "upon determining" or "in response to the determination" or "upon detecting [the specified condition or event]" or "in response to the detection [of the specified condition or event]," depending on the context.

[0010] Referring to Fig. 1, an example of a seating assembly 10 is shown. In some embodiments, the seating assembly 10 is a vehicle seating assembly, e.g., for a land vehicle such as a car, truck, bus, or the like, or for a non-land vehicle such as an aircraft or watercraft. A seating assembly 10 for a land vehicle may, for example, have the shape and size of a front-row driver or passenger seat, a second, third, or other rear-row seat, and may include bench seats, bucket seats, or other seating configurations. Furthermore, the seating assembly 10 may be a non-stowable seat or a stowable seat that is foldable and stowable within a cavity in the vehicle floor. Furthermore, the seating assembly 10 may be configured for applications external to the vehicle, e.g., for furniture.

[0011] In the Fig. 1, the seat assembly 10 includes a seat base 20 and a seat back 22. In some configurations, the seat back 22 may be omitted, e.g., when the seat assembly 10 is configured as a motorcycle seat or stool.

[0012] The seat base 20 is designed to accommodate a seated user and support the pelvis and thighs of the seat user. The seat base 20 includes a seat frame 30, a cushion 32, and a trim cover 34.

[0013] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural elements and may be constructed of any suitable material, such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or combinations thereof. In some configurations, the seat bottom frame 30 includes a panel, a seat pan, a suspension mat, or suspension wires upon which the cushion 32 is disposed.

[0014] The cushion 32 is arranged on the seat base frame 30. The cushion 32 is made of a resilient material that supports the seat occupant and distributes the load forces from the seat occupant to the seat base frame 30. The cushion 32 and the associated manufacturing processes are discussed in more detail below.

[0015] The trim covers 34 cover at least a portion of the cushion 32. In addition, the trim cover 34 provides one or more visible exterior surfaces of the seat back 22. The seat occupant can be positioned on the trim cover 34 when seated on the seat assembly 10. The trim cover 34 is constructed of one or more suitable materials, such as fabric, leather, synthetic leather, vinyl, or combinations thereof. The trim cover 34 may include a plurality of panels assembled together in a suitable manner, e.g., by securing or stitching. The trim covers 34 are attached to the seat bottom frame 30, the seat cushion 32, or both.For example, the trim cover 34 may include trim attachment features attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 and to assist in conforming the trim cover 34 to the contour of the seat bottom frame 30, the cushion 32, or both.

[0016] The seatback 22 is configured to support the back of a seat occupant. The seatback 22 is disposed adjacent the seat bottom 20. For example, the seatback 22 may be disposed above the seat bottom 20 and near the rear of the seat bottom 20. The seatback 22 extends substantially upwardly away from the seat bottom 20. In some configurations, the seatback 22 is attached to the seat bottom 20 and may be pivotable relative to the seat bottom 20. In other configurations, the seatback 22 is not attached to the seat bottom 20. For example, a vehicle seatback may be attached to the body structure of the vehicle, as is the case with some second-row seat arrangements. The seatback 22 includes a seatback frame 40, a cushion 42, a trim cover 44, and optionally, a headrest 46.

[0017] The seatback frame 40 is a structure that supports the cushion 42. The seatback frame 40 includes one or more structural elements and may be made of any suitable material, such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or combinations thereof. In some configurations, the seatback frame 40 includes a panel, a tray, a suspension mat, or suspension wires upon which the cushion 42 is disposed. It is also contemplated that the seatback frame 40 may be integrally formed with the seat bottom frame 30.

[0018] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a resilient material that supports the seat occupant and distributes the load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be formed integrally with the cushion 32 of the seat bottom 20 or separately from the cushion 32 of the seat bottom 20. The cushion 42 and the associated manufacturing processes are explained in more detail below.

[0019] The trim covers 44 cover at least a portion of the cushion 42. In addition, the trim cover 44 provides one or more visible exterior surfaces of the seatback 22. The seat occupant can be positioned on the trim cover 44 when seated on the seat assembly 10. The trim cover 44 is constructed of one or more suitable materials, such as fabric, leather, synthetic leather, vinyl, or combinations thereof. The trim cover 44 may include a plurality of panels assembled together in a suitable manner, e.g., by securing or stitching. The trim covers 44 are attached to the seatback frame 40, the cushion 42, or both.For example, the trim cover 44 may include trim attachment features attached to the seatback frame 40, the cushion 42, or both to prevent removal of the trim cover 44 and to assist in conforming the trim cover 44 to the contour of the seatback frame 40, the cushion 42, or both.

[0020] The headrest 46, if provided, is configured to support the head of a seat occupant. The headrest 46 is disposed on the top of the seatback 22 or at an end of the seatback 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seatback 22 or may be integrally formed with the seatback 22.

[0021] Referring to Fig. 2 shows an example of a cushion 50. For convenience, the cushion is designated by reference number 50. It should be understood that the structure and description of the cushion 50 are applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0022] The cushion 50 consists of a non-foam component or contains at least one non-foam component. The non-foam component is primarily referred to as a fabric element or filament fabric structure, but may also be referred to as a stranded element, looped element, woven element, fabric cushion, fabric structure, stranded fabric, looped fabric, woven fabric, or fabric cushion. Fig. 2, the cushion 50 is illustrated as a non-foam component that does not include a foam component or foam material, such as urethane or polyurethane foam; however, it is contemplated that the cushion 50 may include, in addition to a non-foam component, a foam component or foam material to provide additional cushioning or localized padding for a seat occupant. For example, foam may be provided between the cushion 50 and a trim cover (e.g., trim cover 34, 44) disposed on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam provided with the cushion 50 or eliminating foam from the cushion 50 reduces weight and may improve the support and comfort of a seat occupant. Furthermore, eliminating foam may facilitate recycling of the cushion 50.

[0023] The cushion 50 will be described below primarily in the context of a cushion 50 that does not contain foam. In this context, the cushion 50 consists of filaments of polymeric material that are randomly bent, curled, or looped and bonded together, as explained in more detail below. One filament is bonded directly to another filament and not indirectly to a resin or other intermediate material.

[0024] The filaments, which may also be referred to as strands or threads, are made from any suitable material or materials. In some configurations, the filaments are made from a polymeric or thermoplastic material, such as a polyamide-, polyester-, polyimide-, polyolefin- (e.g., polypropylene-, polyethylene-, etc.-), polystyrene-based thermoplastic resin, or combinations thereof. A polyethylene-based filament, for example, may be made from linear low-density polyethylene (LLPDE). The filament material may be recyclable, unlike foam, or may be more easily recycled than foam. It is also conceivable for a filament to contain reinforcing fibers, and for the reinforcing fibers to be made from a non-thermoplastic material.

[0025] In some configurations, a filament may be a monofilament made of a single material. In some configurations, a filament is made of multiple materials. For example, a multi-material filament may include a core made of a first thermoplastic material and a sheath surrounding the core made of a second thermoplastic material that is different from the first thermoplastic material. It is contemplated that the pad 50 may include a combination of monofilaments and filaments made of multiple materials that are not monofilaments.

[0026] The filaments are randomly bent, looped, crimped, or woven and can be bonded together where one filament touches another, forming a lightweight, air-permeable cushion (e.g., cushions 32 and / or 42) or a woven structure with openings or voids between the filaments. An example of a method for making a woven cushion or mesh structure is disclosed in U.S. Patent Application No. 17 / 555,875, which is hereby incorporated by reference in its entirety. An example of a manufacturing system 60 for making a cushion or filament woven structure is also disclosed in Fig. 3. In this example, the manufacturing system 60 includes a hopper 70, an extruder 72, a hopper 74, a cooling tank 76, and a material handling subsystem 78.

[0027] Referring to Fig. 3, a container or hopper 70 contains material to be extruded, e.g., solid beads, flakes, granules, pellets, or powder made from the material. The hopper 70 provides the material to the extruder 72.

[0028] The extruder 72 melts the feedstock and extrudes the feedstock into filaments 52. The extruder 72 may have any suitable configuration. In some configurations, the extruder 72 includes a barrel that houses a rotating screw and heating elements. The rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction created by the rotation of the screw. The material exits the barrel under pressure and in a molten state and is transported to a nozzle 80 of the extruder 72.

[0029] The nozzle 80, which may also be referred to as a nozzle plate or extrusion nozzle, has several through-holes or filament-forming openings through which the molten material flows. A single filament 52 is extruded from each through-hole. The filaments 52 fall downward from the nozzle 80 into the hopper 74 due to gravity.

[0030] The hopper 74 consolidates or groups the filaments 52 into a more compact arrangement in which the filaments 52 bend, curl, or loop, and one filament 52 touches and is connected to at least one other filament 52. The hopper 74 has a hopper inlet and a hopper outlet that is smaller than the hopper inlet. Individual severed filaments enter the hopper inlet. The filaments 52 bend, curl, or loop, touching each other as they accumulate. The filaments 52 move through the hopper 74 toward the hopper outlet. Some filaments may slide along the hopper 74 or an intermediate film disposed on the hopper 74 as the filaments move toward the hopper outlet. Each element of the set of filaments 52 may be connected to at least one other element of the set of filaments 52.Connections are formed between the filaments 52 at the contact points, while at other locations where one filament 52 is not touching or connected to another filament 52, openings or voids are present between the filaments 52. The entangled and connected filaments 52 pass through the hopper outlet of the hopper 74 and enter the cooling tank 76. For simplicity, the interconnected filaments are referred to as a fabric element or filament fabric structure 90.

[0031] The cooling tank 76 contains a liquid, such as water or a mixture of water and another fluid. The liquid in the cooling tank 76 helps support the entangled and bonded filaments 52 to limit further compaction or consolidation of the filaments 52 into a less open or less porous arrangement and to maintain a desired porosity and density of the filament web structure 90. Thus, the liquid provides some buoyancy or drag, which may result in additional bending, curling, or grinding of the filaments 52 adjacent to the surface of the liquid or within the hopper 74 to further build the filament web structure 90. The liquid also cools the filaments 52 when the filaments 52 are in the liquid.For example, the liquid cools the filaments 52 from the outside to solidify the filaments and prevent the filaments 52 from sticking together at other points. At this point, the filaments 52 are relatively stiff and no longer in a plastic state, so they essentially retain their shape and are not moldable or reshapable without heating.

[0032] The material handling subsystem 78 transports the filament web structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that assist in moving the filament web structure 90 through and out of the liquid. In some configurations, a drag conveyor 92 is provided in the cooling tank 76 to pull the filament web structure 90 away from the hopper 74 and counteract the buoyancy of the filaments 52.

[0033] Other rollers, such as roller 94, keep the filament web structure 90 submerged in the liquid and guide the filament web structure 90 through the cooling tank 76. For example, the roller 94 can guide the filament web structure 90 to a conveyor belt 96 and a vibrating table 98 located outside the cooling tank 76. The vibrating table 98 shakes the filament web structure 90 while it is on the conveyor belt 96 to remove liquid. Alternatively or additionally, the filament web structure 90 can be squeezed to remove liquid, or air can be blown toward the filament web structure 90 to assist in removing liquid from the filament web structure 90, or both. It is also conceivable to allow the filament web structure 90 to drain or to dry in ambient air.

[0034] The manufacturing system 60 described above is a continuous process in which the filament web structure 90 is formed as a continuous structure if filament extrusion is not interrupted. Further processing of the filament web structure 90 is provided after exiting the cooling tank 76 to cut the filament web structure 90 into individual pieces or blanks for individual pads. This processing is performed by a cutting system of the manufacturing system 60. The cutting system may be of any suitable type. For example, the cutting system may use a blade, a knife, a hot knife, a saw, a fluid jet, or the like to cut the filaments 52 of the filament web structure 90 into a blank. The cutting system may be used to shape or contour the blank. A blank may be further shaped or contoured by other manufacturing processes, e.g.,by molding the entire blank or a portion thereof. An example of a piece or blank of the filament fabric structure 90 prior to molding is shown in the center of FIG. Fig. 4 shown.

[0035] Referring to Fig. 4, an example of a mold assembly 100 is shown. The mold assembly 100 may be part of a mold part system of the manufacturing system 60. The mold assembly 100 includes a first mold 102 and a second mold 104. The first mold 102 and the second mold 104 cooperate to define a cavity 106 therebetween, wherein the cavity 106 is shown in the odd-numbered figures of Fig. 7 to 19 are represented by hidden lines.

[0036] The first mold 102 has a first forming surface 110 that faces the filament web structure 90. The first forming surface 110 defines a portion of the cavity 106 and is configured to contact and form the filament web structure 90, as explained in more detail below. A plurality of openings 112 are provided in the first mold 102 and extend from the first forming surface 110. In some configurations, the openings 112 are fluidly connected to the environment. The openings 112 allow gas to exit the cavity 106, liquid to enter the cavity 106, or both, as explained in more detail below. In some configurations, some or all of the openings 112 allow gas to exit the mold assembly 100, liquid to enter the mold assembly 100, or both.

[0037] The second mold 104 has a second forming surface 120 that faces the filamentary fabric structure 90. The second forming surface 120 defines a portion of the cavity 106 and is configured to contact and form the filamentary fabric structure 90, as explained in more detail below. A plurality of openings 122 are provided in the second mold 104 and extend from the second forming surface 120. In some configurations, the openings 122 are fluidly connected to the environment. The openings 122 allow gas to exit the cavity 106, liquid to enter the cavity 106, or both, as explained in more detail below. In some arrangements, some or all of the openings 122 allow gas to exit the mold assembly 100, liquid to enter the mold assembly 100, or both.

[0038] In some configurations, an opening 112, 122 can be selectively connected to the environment or a fluid source external to the mold assembly 100. For example, one or more valves can be connected to an opening 112, 122 and opened to allow fluid to enter or exit the cavity 106. Thus, fluid can be retained within the cavity 106 by closing one or more valves, and fluid can be allowed to exit the cavity 106 by opening one or more valves.

[0039] The first forming surface 110 and the second forming surface 120 are shaped to form or shape the blank of the filament fabric structure 90. For example, the first and second forming surfaces 110, 120 are shaped to form various contours, features, or shapes in the blank of the filament fabric structure 90, e.g., planar shapes; non-planar shapes such as concave, convex, or other complex shapes; channels, recesses, protrusions, curves, bevels, stepped corners, and the like. The cavity 106 may be sized to have a smaller size or volume than the blank of the filament fabric structure 90 such that the mold assembly 100 compresses the blank of the filament fabric structure 90 when the mold assembly 100 is closed (e.g.,when the first mold 102 and the second mold 104 engage or are joined along corresponding mating surfaces that extend around or enclose a corresponding forming surface).

[0040] Referring to Fig. 5 shows a flowchart of a method for manufacturing the filament fabric structure 90. The method may be performed using the manufacturing system 60. The method steps will be described below in the context of forming and reshaping a blank or piece of the filament fabric structure 90 into a desired configuration or shape. Therefore, the method steps will be described beginning with a piece of the filament fabric structure 90 that has been cooled and removed from the cooling tank 76 and cut to a desired size.

[0041] In block 200, the piece of filament fabric structure 90 is placed into the cavity 106 of the mold assembly 100. The piece of filament fabric structure 90 is placed into the cavity 106 of the mold assembly 100 when the mold assembly 100 is opened. The mold assembly 100 is opened by moving at least one of the two molds, the first mold 102 or the second mold 104, such that the cavity 106 is accessible. For example, the first mold 102 may be disposed above the second mold 104 and may be lifted or pivoted away from the second mold 104 to provide a gap between the first mold 102 and the second mold 104 sufficient to allow the piece of filament fabric structure 90 to be placed in the cavity 106.The piece of filament fabric structure 90 can be aligned with the first forming surface 110 and the second forming surface 120, whereby the filament fabric structure 90 can engage or contact the first forming surface 110 and the second forming surface 120 when the mold assembly 100 is closed.

[0042] In block 202, the mold assembly 100 is closed. The mold assembly 100 is closed by moving at least one of the first mold 102 and the second mold 104 such that the first mold 102 and the second mold 104 engage or mate with each other and cooperate to enclose or define the cavity 106. The filament fabric structure 90 is positioned in the cavity 106 between the first mold 102 and the second mold 104, more specifically, between the first forming surface 110 and the second forming surface 120 when the mold assembly 100 is closed.

[0043] In some configurations, the mold assembly 100 is disposed outside a tank 210 that holds a liquid 212 that facilitates the softening and forming of the filament fabric structure 90 when the piece of the filament fabric structure 90 is placed in the cavity 106. An example of a tank 210 and the liquid 212 is shown in Fig. 7, with the tank 210 divided into sections to show its contents. The mold assembly 100 must not be disposed within the tank 210 when the mold assembly 100 is opened and closed. The tank 210 is different from the cooling tank 76 discussed previously. In such a configuration, multiple mold assemblies may be used, with one mold assembly 100 available to receive a piece of the filament fabric structure 90 while another mold assembly 100 having a piece of the filament fabric structure 90 undergoes a forming operation (e.g., heating or cooling), which can help increase throughput.

[0044] In some configurations, the mold assembly 100 is at least partially disposed within the tank 210 when the piece of filament fabric structure 90 is placed within the cavity 106. For example, the first mold 102, the second mold 104, or both may be at least partially disposed within the tank 210 when the piece of filament fabric structure 90 is placed within the cavity 106. In the Fig. In the example shown in Figure 7, the first mold 102 is disposed on top of the second mold 104. In such a configuration, the second mold 104 may be disposed within the tank 210 once the piece of filamentary fabric structure 90 is placed within the cavity 106. The first mold 102 may then be lowered into the tank 210 and positioned to engage and mate with the second mold 104. As another example, the first mold 102 may be pivotally attached to the second mold 104 disposed within the tank 210. In such a configuration, the first mold 102 may be disposed outside the tank 210, partially within the tank 210, or entirely within the tank 210 when the mold assembly 100 is open, and the first mold 102 may be disposed partially or entirely within the tank 210 when the mold assembly 100 is closed.Providing at least a portion of the mold assembly 100 within the tank 210 may reduce or eliminate material handling associated with transporting the mold assembly 100 to or from the tank 210.

[0045] In block 204, liquid 212 is added to the cavity 106 of the mold assembly 100. The liquid is supplied to the cavity 106 after the piece of filament fabric structure 90 has been placed in the cavity 106. The liquid 212 may be of any suitable type. For example, the liquid 212 may be water or a mixture of water and one or more other liquids.

[0046] The liquid 212 is provided to the cavity 106 at a temperature above a first temperature threshold sufficient to heat the filaments 52 so that the filaments 52 of the filamentary fabric structure 90 can be reshaped or reshaped.

[0047] More specifically, the thermal energy provided by the liquid 212 heats the filaments 52 to a temperature that allows the filament material to be reshaped or reshaped into a different shape by the compressive force exerted by the mold assembly 100 against the filament web structure 90 therein. Thus, the liquid 212 softens the filament web structure 90 within the cavity 106 so that the shape of the filament web structure 90 conforms to a forming surface, such as the first forming surface 110, the second forming surface 120, or both. The thermal energy provided by the liquid 212 softens or plasticizes the filaments 52 to make the filaments 52 compliant without melting the filaments 52. As used herein, the term “compliant” means that the filament material is in a state (e.g., at a temperature) where its shape can be permanently changed in the mold assembly 100.The liquid 212 is provided such that the temperature of the filaments 52 remains below the melting temperature of the filament material. For example, the filaments 52 may be heated by the liquid 212 to a temperature 10 to 70°C below the melting temperature of the thermoplastic material. In this way, a filament 52 is heated in a manner sufficient to plastically shape or reshape a filament 52, but insufficient to form a new bond between one filament 52 and another filament 52 or between the filament and itself.

[0048] The first temperature threshold may vary depending on the filament material used. For example, the liquid 212 may be heated to a temperature of 80 to 100°C if the filaments 52 are made of linear low-density polyethylene (LLPDE). The temperature may be monitored or determined using a temperature sensor, such as a thermocouple, a thermistor, a resistance temperature sensor, a semiconductor-based temperature sensor, or the like.

[0049] The addition of liquid 212 into the cavity 106 can be done in various ways, examples of which are best described in the Fig. 6-11. In some configurations, such as those shown in Fig. 6-9, liquid 212 is added to the cavity 106 when the mold assembly 100 is disposed in the tank 210. In other configurations, such as the configuration shown in Fig. 10 and Fig. 11, adding liquid 212 includes filling the cavity 106 with the liquid 212 without using a tank 210.

[0050] Referring to the Fig. 6 and Fig. 7, in some embodiments, the mold assembly 100 is placed in a tank 210 containing the liquid 212. In other words, the tank 210 contains the liquid 212 before the mold assembly 100 is placed in the tank 210. Providing liquid in the tank 210 prior to placing the mold assembly 100 in the tank 210 can reduce the cycle time compared to placing the mold assembly 100 in the tank 210 and then sufficiently filling the tank 210 with liquid. Thus, the mold assembly 100 is placed in the tank 210 after the filament fabric structure 90 has been placed in the cavity 106. The mold assembly 100 is placed in the tank 210 when the mold assembly 100 is closed. The mold assembly 100 may be placed into the tank 210 in any suitable manner.For example, the mold assembly 100 may be lowered into the tank 210 using a hoist or a crane, the mold assembly 100 may be placed on a platform that is lowered into the tank 210, or the like.

[0051] By placing the mold assembly 100 in the tank 210 containing the liquid 212, the liquid 212 can enter the cavity 106. The liquid 212 enters various openings of the mold assembly 100 and flows through one or more openings 112, 122 into the cavity 106. As the liquid 212 enters the cavity 106, the air is vented from the cavity 106 via various recesses or openings 112, 122. For example, the liquid 212 can enter recesses and openings 122 of the second mold 104 when the mold assembly 100 is lowered into the liquid 212. Air exits the cavity 106 through openings 112 in the first mold 102, openings 122 in the mold 104, or both as the mold assembly 100 is lowered into the liquid 212. The mold assembly 100 is partially or fully submerged in the liquid 212.For example, the mold assembly 100 may be positioned in the liquid 212 such that the cavity 106 is below the top surface 214 of the liquid 212 so that the liquid 212 can fill the cavity 106.

[0052] The liquid 212 flows through the cavities in the filament fabric structure 90 within the cavity 106 as the liquid 212 fills the cavity 106. Thus, the liquid 212 may be distributed substantially evenly throughout the thickness of the filament fabric structure 90, which may help provide substantially uniform heating of the filaments 52 of the filament fabric structure 90.

[0053] Referring to the Fig. 8 and Fig. 9, in some embodiments, the liquid 212 is added to the tank 210 after the mold assembly 100 has been placed in the tank 210. For example, the tank 210 may be empty or contain the liquid 212 at a sufficiently low level so that the liquid 212 cannot enter the cavity 106. The liquid may be stored in a storage tank, where it may be maintained at a desired temperature or insulated to prevent heat loss. Then, the tank 210 may be filled with the liquid 212 to a sufficient level, or at least partially filled, so that the liquid 212 fills the cavity 106, as previously described. This is described in Fig. 9, which shows on the left an empty tank 210 in which a closed mold assembly 100 is arranged, and on the right an example of a tank 210 filled with liquid 212 to a level that floods the mold assembly 100.

[0054] Referring to the Fig. 10 and Fig. 11, in some embodiments, the liquid 212 is provided to the cavity 106 without placing the mold assembly 100 in a tank and without submerging or partially submerging the mold assembly 100 in the liquid 212. In such a configuration, the mold assembly 100 may include fewer recesses or openings, as previously described, and may be configured such that the first mold 102 is sealed from the second mold 104 when the mold assembly 100 is closed. The cavity 106 may be sealable or isolable from the ambient air in this configuration. The liquid 212 is provided to the cavity 106, for example, from a fluid source 220. The fluid source 220 is fluidly connected to the cavity 106. For example, the fluid source 220 may be connected to the mold assembly 100 via a conduit, such as a hose. B. a pipe, a hose, a tube or the like.The mold assembly 100 may include one or more channels fluidly connected to the conduit and extending to a corresponding molding surface. The fluid source 220 may include a pump that pressurizes the liquid 212 and forces it into the cavity 106. Gas or air in the cavity 106 may be vented as the cavity 106 is filled in a manner known to those skilled in the art. The liquid level in the cavity 106 may be monitored visually, e.g., with a sight glass, or with a sensor, e.g., a liquid level sensor such as an optical sensor, a capacitive sensor, an ultrasonic sensor, a pressure-based sensor, a cell, or the like.

[0055] Once the cavity 106 is filled with the liquid 212, the liquid 212 is retained within the cavity 106 for a predetermined period of time. The predetermined period of time may vary based on numerous factors, such as the filament material, the temperature of the liquid, the temperature of the mold assembly 100, the temperature of the piece of filament fabric structure 90 when inserted into the cavity 106, and the like. The predetermined period of time may be determined based on development testing. As a non-limiting example, the predetermined period of time may be greater than one minute, e.g., between 1 and 6 minutes; however, it is contemplated that the predetermined period of time may be less than one minute in some configurations. The liquid 212 will not exit the mold assembly 100 when the liquid 212 is retained within the cavity 106.For example, the cavity 106 may be filled with the liquid 212, and one or more valves may be closed to prevent the liquid 212 from exiting the cavity 106 and to prevent further liquid 212 from entering the cavity 106. In this way, the liquid 212 will not circulate into or out of the cavity 106 when the liquid 212 is retained in the cavity 106.

[0056] In Block 206 in Fig. 5, the filament fabric structure 90 is cooled within the cavity 106 of the mold assembly 100. The mold assembly 100 remains closed while the filament fabric structure 90 is cooled. Removing the filament fabric structure 90 from the mold assembly 100 when the filament fabric structure 90 is in a compliant, softened state may result in the conformal shape provided by the molding surface being inadvertently altered or lost. To overcome this problem, the filament fabric structure 90 is cooled within the mold assembly 100 to lock the shape of the filament fabric structure 90 to the molding surface. Cooling the filament fabric structure 90 in the mold assembly 100 includes cooling the filament fabric structure 90 with a fluid to at least a second temperature threshold that is lower than the first temperature threshold.The second temperature threshold is selected to be any temperature that places the filament fabric structure 90 in a non-compliant state. For example, the second temperature threshold may be below 85°C for linear low-density polyethylene. The cooling fluid may be a gas, a liquid, or a combination of gas and liquid.

[0057] The filament fabric structure 90 can be cooled in various ways, some examples of which are described with reference to the Fig. 12-19 are discussed. In the Fig. 12-15, cooling the filament fabric structure 90 includes removing the mold assembly 100 from the tank 210. In the Fig. 16-19, cooling the filament fabric structure 90 does not include removing the mold assembly 100 from the tank 210.

[0058] Referring to the Fig. 12 and Fig. 13, in some embodiments, cooling the filament fabric structure 90 includes removing the mold assembly 100 from the tank 210 and cooling the filament fabric structure 90 with a gas. This is shown in Fig. 13. The mold assembly 100 can be removed from the tank 210 by positioning the cavity 106 or the entire mold assembly 100 above the upper surface 214 of the liquid 212, e.g., with a hoist or a movable platform. The liquid 212 drains from the cavity 106 as the mold assembly 100 is removed from the liquid 212 via the various openings in the mold assembly 100. The liquid 212 is replaced with a gas from the environment as the liquid 212 drains from the cavity 106. The gas can be, for example, air. The gas entering the cavity 106 is provided at a temperature that is below the second predetermined temperature. As a result, the filament fabric structure 90 is cooled with the gas entering the cavity when the mold assembly 100 is removed from the tank 210.When the mold assembly 100 is removed from the tank 210, the tank 210 can accommodate another filament fabric structure 90, which can contribute to an increase in throughput.

[0059] Referring to the Fig. 14 and Fig. 15, in some embodiments, cooling the filament fabric structure 90 includes removing the mold assembly 100 from the tank 210 and cooling the filament fabric structure 90 with a liquid in a second tank 230. This is shown in Fig. 15. The mold assembly 100 is removed from the tank 210 and placed in the second tank 230. The mold assembly 100 may be removed from the tank 210 and lowered or otherwise positioned into the second tank 230 using a hoist, crane, cherry picker, or other suitable material handling device. The liquid 212 in the tank 210 drains from the cavity 106 when the mold assembly 100 is removed from the liquid 212 and is replaced with a gas, such as air, as previously described. Consequently, some gas cooling may occur during transport of the mold assembly 100 from the tank 210 to the second tank 230. The gas is replaced by the liquid 232 in the second tank 230 when the mold assembly 100 is lowered into the liquid 232.The liquid 232 in the second tank 230 is provided at a temperature below the second predetermined temperature. As a result, the filament fabric structure 90 in the mold assembly 100 is cooled by the liquid 232 entering the cavity 106 when the mold assembly 100 is placed in the second tank 230, thereby defining the shape of the filament fabric structure 90 to the molding surface of the mold assembly 100.

[0060] Referring to the Fig. 16 and Fig. 17, in some embodiments, the filament fabric structure 90 is cooled in the tank 210 with a gas. The filament fabric structure 90 can be cooled in the tank 210 by draining the liquid 212 from the tank 210 so that gas from the environment, e.g., air, enters the cavity 106 and cools the filament fabric structure 90. This is similar to the arrangement according to the Fig. 12 and Fig. 13, but instead of removing the mold assembly 100 from the liquid 212 in the tank 210, the liquid 212 is removed from the tank 210 and the mold assembly 100. The liquid 212 may be removed from the tank 210 by draining the tank 210, for example, by opening a drain valve. The tank 210 is drained at least to a level below the cavity 106, allowing gas to enter the cavity 106 instead of the liquid 212. Draining the tank 210 may help avoid material handling operations associated with removing the mold assembly 100 from the tank 210, which may contribute to a reduction in cycle time.

[0061] In the Fig. 18 and Fig. 19, in some embodiments, the filament fabric structure 90 is cooled with a liquid in the tank 210. This can be done in several ways.

[0062] In some arrangements, the liquid 212 in the tank 210 is cooled to a temperature below the second temperature threshold, thereby cooling the filament fabric structure 90 in the mold assembly 100 to define the shape of the filament fabric structure 90 to the forming surface. For example, the liquid 212 may be directed from the cavity 106 to a heat exchanger or other cooling device that cools the liquid 212. The liquid 212 may be returned to the cavity 106 at a lower temperature to facilitate cooling of the filament fabric structure 90. The liquid 212 may be returned to the cavity 106 below the second temperature threshold or circulated through the heat exchanger or cooling device multiple times to cool the liquid 212 sufficiently below the second temperature threshold.

[0063] In some configurations, the liquid 212 is drained from the cavity 106 and replaced with a liquid having a temperature below the second temperature threshold. For example, the heated liquid 212 may be drained from the tank 210 and thus from the cavity 106. Subsequently, the tank 210 may be filled with a liquid 212' having a temperature below the second temperature threshold, thereby filling the cavity 106 with the cooler liquid 212'. Cooling with a liquid rather than a gas may result in faster cooling of the filament fabric structure 90.

[0064] In configurations that do not use Tank 210, such as those in the Fig. 10 and Fig.11, cooling may be achieved by draining the liquid 212 from the cavity 106 after the liquid 212 has been maintained in the cavity 106 for the predetermined period of time and replacing the liquid 212 with a gas. For example, the liquid 212 may be drained from the cavity 106 and replaced with a gas having a temperature below the second temperature threshold that cools the filament fabric structure 90.

[0065] In some configurations that do not utilize a tank 210, cooling may be achieved by draining the liquid 212 from the cavity 106 after the liquid 212 has been maintained in the cavity 106 for the predetermined period of time, and then providing liquid having a temperature below the second temperature threshold into the cavity 106 to cool the filament fabric structure 90. The heated liquid that is drained may be stored to maintain the heated liquid at an elevated temperature, which may reduce energy consumption compared to a configuration in which a liquid having a temperature below the second temperature threshold is mixed with the heated liquid to lower the overall temperature of the liquid.

[0066] In block 208, the mold assembly 100 is opened, and the cooled filament fabric structure 90 is removed from the cavity 106. The cooled filament fabric structure 90 may now be ready for installation into a seat assembly or for further manufacturing steps.

[0067] Set 1. A method comprising: placing a filament fabric structure in a cavity of a mold assembly, the mold assembly including a molding surface; adding liquid having a temperature above a first temperature threshold into the cavity, thereby softening the filament fabric structure and conforming a shape of the filament fabric structure to the molding surface; and cooling the filament fabric structure in the mold assembly to commit the shape of the filament fabric structure to the molding surface.

[0068] Sentence 2. The method according to sentence 1, wherein liquid is added to the cavity when the mold assembly is arranged in a tank.

[0069] Clause 3. The method of clause 2, wherein at least a portion of the mold assembly is disposed within the tank when the fabric member is placed within the cavity of the mold assembly.

[0070] Sentence 4. The method of sentence 2, further comprising placing the mold assembly in the tank after the fabric element has been introduced into the cavity.

[0071] Clause 5. The method of clause 4, wherein the tank contains liquid before the mold assembly is placed in the tank.

[0072] Sentence 6. The method of sentence 4 or sentence 5, wherein placing the mold assembly in the tank includes immersing the mold assembly in the liquid.

[0073] Clause 7. The method of clause 4, wherein adding liquid includes at least partially filling the tank with liquid after the mold assembly has been placed in the tank.

[0074] Sentence 8. The method of any preceding sentence, wherein cooling the fabric member includes removing the mold assembly from the tank.

[0075] Sentence 9. The method of sentence 8, wherein cooling the fabric element includes cooling the fabric element with a gas.

[0076] Clause 10. The method of clause 9, wherein cooling the fabric member includes cooling the fabric member with air entering the cavity when the mold assembly is removed from the tank.

[0077] Clause 11. The method of any one of clauses 8 to 10, wherein cooling the fabric member includes placing the mold assembly in a second tank containing a liquid having a temperature below a second temperature threshold, wherein the liquid in the second tank enters the cavity and cools the fabric member in the mold assembly to define the shape of the fabric member onto the forming surface.

[0078] Sentence 12. The method of sentences 2 to 7, wherein cooling the fabric element comprises cooling the fabric element in the tank.

[0079] Clause 13. The method of clause 12, wherein cooling the fabric member includes draining liquid from the tank so that air enters the cavity and cools the fabric member.

[0080] Clause 14. The method of clause 12, wherein cooling the fabric member includes cooling the liquid in the tank and cavity below a second temperature threshold, thereby cooling the fabric member in the mold assembly to define the shape of the fabric member to the forming surface.

[0081] Sentence 15. The method of sentence 12 or sentence 13, wherein cooling the fabric member includes draining liquid from the cavity and adding liquid below a second temperature threshold to the tank such that the liquid at least partially floods the mold assembly and enters the cavity, thereby defining the shape of the fabric member to the forming surface.

[0082] Clause 16. The method of clause 1, wherein adding liquid includes filling the cavity with liquid and maintaining the liquid in the cavity for a predetermined period of time.

[0083] Clause 17. The method of clause 16, wherein the liquid does not leak from the mold assembly when the liquid is retained in the cavity.

[0084] Clause 18. The method of clause 16 or clause 17, wherein cooling the fabric member includes replacing fluid in the cavity with fluid having a temperature below a second temperature threshold that cools the fabric member in the mold assembly to define the shape of the fabric member to the forming surface.

[0085] Clause 19. The method of clause 16 or clause 17, wherein cooling the fabric member includes draining liquid from the cavity after the liquid has been maintained in the cavity for the predetermined period of time, and then providing liquid having a temperature below a second temperature threshold into the cavity that cools the fabric member in the mold assembly to define the shape of the fabric member to the forming surface.

[0086] Sentence 20. Any of the preceding Sentences 1-20 in any combination.

[0087] Sentence 21. A cushion for a seating assembly, the cushion comprising the fabric member formed by the method of any one of the preceding sentences.

[0088] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the description are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 510,793

[0001] US 17 / 555,875

[0026]

Claims

[1] A method comprising: Placing a fabric element in a cavity of a mold assembly, the mold assembly comprising a molding surface; Adding liquid having a temperature above a first temperature threshold into the cavity, thereby softening the fabric element and adapting a shape of the fabric element to the shaping surface; and Cooling the fabric element in the mold assembly to define the shape of the fabric element onto the forming surface. [2] The method of claim 1, wherein liquid is added to the cavity when the mold assembly is disposed in a tank. [3] The method of claim 2, wherein at least a portion of the mold assembly is disposed in the tank when the fabric member is placed in the cavity of the mold assembly. [4] The method of claim 2, further comprising placing the mold assembly in the tank after the fabric member has been placed in the cavity. [5] The method of claim 4, wherein the tank contains liquid before the mold assembly is placed in the tank. [6] The method of claim 5, wherein placing the mold assembly in the tank includes immersing the mold assembly in the liquid. [7] The method of claim 4, wherein adding liquid includes at least partially filling the tank with liquid after the mold assembly has been placed in the tank. [8] The method of claim 2, wherein cooling the fabric member includes removing the mold assembly from the tank. [9] The method of claim 8, wherein cooling the fabric member includes cooling the fabric member with a gas. [10] The method of claim 9, wherein cooling the fabric member includes cooling the fabric member with air entering the cavity when the mold assembly is removed from the tank. [11] The method of claim 8, wherein cooling the fabric member includes placing the mold assembly in a second tank containing a liquid having a temperature below a second temperature threshold, the liquid in the second tank entering the cavity and cooling the fabric member in the mold assembly to define the shape of the fabric member to the forming surface. [12] The method of claim 2, wherein cooling the fabric member comprises cooling the fabric member in the tank. [13] The method of claim 12, wherein cooling the fabric member includes draining liquid from the tank so that air enters the cavity and cools the fabric member. [14] The method of claim 12, wherein cooling the fabric member includes cooling the liquid in the tank and cavity below a second temperature threshold, thereby cooling the fabric member in the mold assembly to define the shape of the fabric member to the forming surface. [15] The method of claim 12, wherein cooling the fabric member includes draining liquid from the cavity and adding liquid below a second temperature threshold to the tank such that the liquid at least partially floods the mold assembly and enters the cavity, thereby defining the shape of the fabric member to the forming surface. [16] The method of claim 1, wherein adding liquid includes filling the cavity with liquid and maintaining the liquid in the cavity for a predetermined period of time. [17] The method of claim 16, wherein liquid does not leak from the mold assembly when liquid is retained in the cavity. [18] The method of claim 16, wherein cooling the fabric member includes replacing liquid in the cavity with liquid having a temperature below a second temperature threshold that cools the fabric member in the mold assembly to define the shape of the fabric member to the forming surface. [19] The method of claim 16, wherein cooling the fabric member includes draining liquid from the cavity after the liquid has been maintained in the cavity for the predetermined period of time, and then providing liquid at a temperature below a second temperature threshold in the cavity that cools the fabric member in the mold assembly to define the shape of the fabric member to the forming surface. [20] A cushion for a seating arrangement, the cushion comprising the fabric element formed by the method of claim 1.

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