Pillow assembly

Abstract

A product is provided with a body formed from a plurality of filaments of expanded thermoplastic resin with a non-rectangular cross-section. The concentration of the plurality of filaments is greater around the circumference than within the circumference, in order to provide a contact area around the circumference.

Description

Cross-reference to related registrations

[0001] This application claims priority over the Danish patent application with serial number PA 2023 70425, filed on August 21, 2023. This Danish patent application, in turn, claims priority over the provisional US patent application with serial number 63 / 435,952, filed on December 29, 2022. Technical field

[0002] Various designs relate to cushion assemblies for seat assemblies. Brief description of the drawings Fig. Figure 1 is a perspective front view of a seat assembly according to one embodiment; Fig. Figure 2 is a perspective partial front view of a padding pad of the seat assembly of Fig. 1, according to one embodiment; Fig. Figure 3 is a schematic view from the front of a system for manufacturing the seat cushion pad of Fig. 2; Fig. Figure 4 is a front view of a padding pad; Fig. Figure 5 is an enlarged perspective front view of a tool plate of the system by Fig. 3; and Fig. Figure 6 is an enlarged perspective front view of the system of Fig. 3. Detailed description

[0003] Reference is now made in detail to embodiments, examples of which are shown in the accompanying figures. The following detailed description specifies numerous details to provide a comprehensive understanding of the various described embodiments. However, it will be clear to a person skilled in the art that the various described embodiments can also be implemented without these specific details. In other cases, known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0004] It is 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 in size to show details of certain components. Therefore, specific structural and functional details disclosed here are not to be understood as limiting, but merely as a representative basis to show the person skilled in the art how embodiments according to the disclosure can be used in various ways.

[0005] “One or more” includes a function executed by one element, a function executed by more than one element (e.g., in distributed form), multiple functions executed by one element, multiple functions executed by multiple elements, or any combination of the above.

[0006] It is also understood that, although the terms "first," "second," etc., are used here in some cases to describe different elements, these elements should not be restricted by these terms. These terms are used only to distinguish one element from another. For example, a first contact could be called a second contact, and likewise a second contact could be called a first contact, without exceeding the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0007] The terminology used in the description of the various embodiments described herein serves only to describe specific embodiments and is not to be understood as limiting. As used in the description of the various embodiments and the accompanying claims, the singular forms "a", "an", and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It is also understood that the term "and / or", as used herein, refers to and includes any and all possible combinations of one or more of the associated listed elements.It is further understood that the terms “contains”, “containing”, “comprises” and / or “comprehensive”, when used in this specification, specify the presence of the specified features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0008] The term "if" used here can be understood, depending on the context, as "when" or "at" or "in response to the finding" or "in response to the recognition." Similarly, the expression "when it is found" or "when [a particular condition or event] is found" is interpreted, depending on the context, as meaning "at the finding" or "in response to the finding" or "upon the finding [of the particular condition or event]" or "in response to the finding [of the particular condition or event]."

[0009] Fig. Figure 1 shows a seat assembly 20 as a vehicle seat assembly 20 according to one embodiment. Although the vehicle seat assembly 20 is shown and described, any seat assembly 20 can be used. The seat assembly 20 can be used in a land vehicle, an aircraft, a watercraft, or the like. The seat assembly 20 can also be used as an office chair, a comfort chair, or the like.

[0010] The illustrated seat assembly 20 includes a seat cushion 22 that supports the pelvis and thighs of a seated occupant. The seat assembly 20 also includes a seat back cushion 24 to support the back and shoulders of the seated occupant. A trim cover 26 is provided over the seat cushions 22 and 24 to conceal them and provide a uniform and smooth contact surface for the occupant.

[0011] In Fig. Figure 2 shows one of the seat cushions 22 partially removed from the seat assembly 20. The seat cushion 22 is formed from a plurality of threads 28 made of an extruded, expanded thermoplastic resin. The seat cushion 22 is also formed with a layer or film 30 made of extruded thermoplastic resin threads 28, which are concentrated and connected to the plurality of threads 28 and uniformly shaped.

[0012] In Fig. 3. The seat cushions 22 and 24 are manufactured using a system 34 and a process made of extruded thermoplastic resin fabric. A container 36 holds a supply of material to be extruded, e.g., as solid granules or pellets. The material can be provided by plastic, e.g., linear low-density polyethylene (LLDPE). The material is fed from the container 36 to an extruder 38.

[0013] The extruder 38 melts the material and transports it to a die plate 40. In a non-restrictive example, the extruder 38 contains a cylinder that houses a rotatable screw and heating elements. The rotation of the screw forces the material to move through the cylinder, and the friction generated by the screw's rotation contributes to heating the material. The material exits the extruder 38 under pressure and in a molten state.

[0014] The die plate 40 extrudes the material into filaments 42. The die plate 40 can be provided as described below, depending on the direction of extrusion with respect to the final element 22, 24 being produced. More precisely, the die plate 40 has several small circular through-holes or openings through which the molten material flows. A single filament 42 is extruded from each hole in the plate. The filaments 42 fall downwards from the die plate into a hopper 44 under system pressure and gravity, as described below. The hopper 44 can have a cross-section that is the same as, or different from, a shape defined jointly by, the openings in the die plate 40.

[0015] The funnel 44 helps to consolidate or group the filaments 42 into a more compact arrangement in which the filaments 42 bend or intertwine, and each filament 42 touches and connects to at least one other filament 42. The funnel 44 has a funnel inlet and a funnel outlet, which is smaller than the funnel inlet. The funnel 44 is narrower at the funnel outlet than at the funnel inlet. Individual detached filaments 42 enter the funnel inlet, bend / intertwine, and touch each other as they accumulate and slide down the funnel 44 toward the funnel outlet, and the consolidated filament structure 46 exits the funnel outlet and enters a water tank directly.

[0016] A liquid reservoir 48 contains water 50, coolant, or another fluid and receives the consolidated filament structure 46 from the hopper 44. The liquid 50 in the bath 48 helps to temporarily support the consolidated filament structure 46 to prevent it from collapsing or condensing into a less open or less porous arrangement and to maintain the desired porosity and density. As such, the liquid 50 provides a degree of resistance that causes additional bending and entangling of the filaments 42 to further build the consolidated filament structure 46. Secondly, the liquid 50 cools the filaments 42 from the outside to solidify them and prevent them from joining together at further points.

[0017] Tank 48 contains various rollers and conveyors that help move the consolidated filament structure 46 through and out of the liquid 50, such as a tractor conveyor 52. The speed of the rollers and conveyors can be controlled so that the consolidated filament structure 46 is moved away from the hopper 44 at a speed that depends on the speed at which the consolidated filament structure 46 leaves the hopper 44.

[0018] Other rollers, such as roller 54, help to keep the consolidated filament structure 46 immersed in the liquid 50 and guide it through the liquid 50 to a conveyor belt 56 and a vibrating table 58, which are located outside the tank 48. The vibrating table 58 shakes the consolidated filament structure 46 while it is on the conveyor belt 56 to remove the liquid 50. Additionally or alternatively, compressed air can be blown onto the consolidated filament structure 46 and / or the consolidated filament structure 46 can be squeezed to remove the liquid 50. The consolidated filament structure 46 can then be cut to the desired size and shape.

[0019] Fig. Figure 4 shows a padding pad 60, which is used with the system 34. Fig. 3 was formed. The padding pad 60 is extruded from system 34 and then cut from the filament structure 46. The padding pad 60 contains a body formed from a plurality of threads 28 to create a uniform body. The padding pad 60 has a cross-section that is in Fig. Figure 4 shows that the cross-section is not rectangular, so the padding pad 60 is extruded into the desired shape to avoid or minimize secondary forming processes and material waste. The padding pad 60 can be a seat cushion or part of a seat cushion that is assembled with other seating components. The padding pad 60 can be used for any type of upholstery, such as seat cushions, backrests, headrests, armrests, leg rests, and the like.

[0020] Fig. Figure 5 shows a tool 62 located in the funnel 44 of the system 34 of Fig. 3 is provided. With further reference to Fig. In section 5, the tool 62 is provided as a plate 62, which is referred to as the funnel plate 62. An opening 64 is formed through the plate 62 to guide and funnel the threads or molten filaments 42 of thermoplastic resin into the cooling chamber 48. The through-opening 64 is dimensioned to correspond to the overall profile or circumference of the padding pad 60 when viewed from the outside. Fig. 4. Therefore, the molten resin threads 42 are collected, guided, and cooled in the padding pad 60. The plate 62 forms the fabric from the molten resin threads 42 into the overall profile of the cushion 22 as the threads 42 curl, loop, and cross. The plate 62 shapes the fabric before it solidifies into the non-woven fabric of the padding pad 60.

[0021] The tool plate 62 includes a leading edge 66 around the through-hole 64 at one end of the plate 62, where the filament is inserted. The leading edge 66 can be a chamfer, as shown in the figure, a rounded edge, or the like. The leading edge 66 guides the filament strands 42 into the plate opening 64.

[0022] Fig. Figure 6 shows the tool plate 62, which is mounted in the hopper 44 of the system 34. The tool plate 62 is covered with a fabric material 68, which covers the tool plate 62 for receiving and contact with the filaments 42. The fabric material 68 is lubricated to facilitate cooling and resistance against the filaments 42 as they move along the leading edge 66 of the plate 62. The fabric material 68 serves to retain the lubricant on the leading edge 66 during the dispensing process. The lubricant can be water 50 or otherwise identical to the fluid 50 in the tank 48. The system 34 includes fluid lines 70 to convey the lubricant from the tank 48 to the fabric material 68.

[0023] Fig. Figure 6 shows a continuous flow of molten thermoplastic resin from filaments 42 out of the extrusion die 40. Unless otherwise specified, the term "molten," as used here, means that the material is at least partially molten. It does not necessarily mean that the material is in a completely liquid state; rather, it means that the material is not completely solid and can still flow through the elements of the system 34. For example, the molten material may still flow through the die plate 40, but it may be very viscous and begin to solidify. Once the solid granules of the polymer material have melted in the extruder 38, the material begins to cool because it is no longer being moved by the extruder screw and is moving away from all heating elements.At various points in process 34, the material may have a higher or lower viscosity, but if it is still partially molten and can flow - even slowly - the term "molten" is used here.

[0024] Fig. Figure 6 shows how the molten filaments 28 and films 30 enter the funnel plate 62 to reach the cooling chamber 48. In the cooling chamber 48, the flow of the filaments 42 through the fluid is resisted, causing them to curl, bend, and bond together. A subset of the filaments 42 is further retained and curled along the leading edge 66 to provide a denser concentration of filaments 28 around the circumference, compared to the concentration of filaments staggered within the circumference. This denser concentration of filaments 28 around the circumference forms the film or skin 30. The filaments 42 cool and solidify in the cooling chamber 48 as the filaments 28 and films 30, forming a uniform body as the cushioning pad 60.

[0025] The extrusion die 40 contains a plurality of nozzles 72 that exceed a total area of ​​the through-hole 64 of the plate 62, such that the filaments 42 contact the fabric 68 along the leading edge 66. The nozzles 72 are arranged in an array, and a number of rows of filaments 42 can be selected to contact the leading edge 66. For example, if one row of filaments 42 contacts the leading edge 66 and converges at the edge 66, the skin 30 will be denser than the remaining filaments 28. If two rows of filaments 42 contact the leading edge 66, a denser (or medium-density) skin 30 is produced. If three rows of filaments 42 are aligned around the perimeter to contact the leading edge 66 and converge there, a thick skin 30 is produced. Furthermore, if all nozzles 72 are aligned with the through-hole 64, little or no skin 30 will be provided around the circumference.

[0026] The outer skin 30 provides surface tension for a continuous seating surface on the cushion 22, similar to a skin along a foam cushion, to offer support and comfort to the occupant. The skins 30 also provide surfaces for attaching other seat components by means of an adhesive, hook and loop fastener, or the like. As in Fig. As shown in Figure 2, a further layer 74 is attached to the outer film 30. According to one embodiment, the layer 74 is the cladding cover 26. According to another embodiment, the layer 74 is an actuator 74, such as an air bubble assembly 74. According to a further embodiment, the layer 74 is a heat transfer layer 74, for example, a heating mat 74. The layer 74 can also be a cladding component 74 or a tab for attachment to other cladding components, such as a carrier 76 ( Fig. 1) The layer 74 can also be a support body 74 for attachment to a seat frame 78 ( Fig. 1).

[0027] Seat cushions are often molded from foam. Foam cushions require special tools for molding each component of the cushion. Unlike previous molds, the padding pad 60 is made using a different mold. Fig. 4 the tool plate 62 of the Fig. 7 used for casting. System 34 of the Fig. 3 and Fig.6 contains flexible equipment suitable for producing various cushions with different tool plates. When using tool plate 62, the nozzles 72 located outside the circumference of the leading edge 66 are closed, so that the extruded filaments 42 are discharged into the opening 64 and the leading edge 66. The opening or closing of each nozzle 72 can be adjusted for each tool plate 62. Likewise, the number of nozzles 72 outside the opening 64 can be adjusted to determine the filament concentration on the skin 30.

[0028] The tool plate 62 gives the cushion 22 its shape before the threads 28 cool, harden, and solidify into the non-woven fabric cushion material. Secondary forming processes for creating shape, contour, seating surfaces, and connecting surfaces are unnecessary. The upholstery pad 60 is cut from the otherwise continuously formed fabric assembly 46. Alternatively, the cushion 22 can also be formed from a plurality of fabric assembly segments 60 with a sequential overall profile, which are combined in the cover 26. The segments 60 can be glued, welded, or otherwise joined together.

[0029] The tool plate 62 can have different angles along various surfaces of the leading edge 66 to achieve the desired material resistance. The tool plate 62 can be formed using a rapid manufacturing process, e.g., by machining, 3D printing, or similar methods. The tool plate 62 can be machined from a metal alloy or a polymeric material. Likewise, the tool plate 62 can be printed from a polymeric material.

[0030] Although various embodiments are described above, it is not intended that these embodiments describe all possible forms according to the disclosure. In this respect, the words used in the description are descriptive rather than limiting, and it is understood that various modifications may be made without deviating from the essence and scope of the disclosure. Furthermore, the features of different embodiments may be combined to form further embodiments according to the disclosure. QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] PA 2023 70425

[0001] US 63 / 435,952

[0001]

Claims

[1] A product comprising a body formed from a plurality of filaments of expanded thermoplastic resin having a non-rectangular cross-section, wherein a concentration of the plurality of filaments around a perimeter of the non-rectangular cross-section is greater than within the perimeter in order to provide a contact area around the perimeter. [2] The product according to claim 1, wherein the plurality of threads around the circumference of the non-rectangular cross-section with the concentration greater than within the circumference is further defined as a plurality of thread rows. [3] The product according to claim 1 or claim 2, wherein the body is dimensioned to provide a cushioning pad. [4] A seating assembly comprising: a seat frame; and the padding pad according to claim 3. [5] A process for manufacturing a product, comprising: Delivery of an outer plurality of threads of a molten thermoplastic resin through a tool having an opening dimensioned to fit the overall cross-section of a product in order to engage a leading edge and then to pass through the opening, and an inner plurality of threads of the molten thermoplastic resin to pass through the opening without interfering with the leading edge; and Resisting a flow of the majority of threads while the majority of threads are cooled, wherein the resistance provides a uniform non-woven body in the form of an overall circumference of the product with an increased concentration of threads along a circumference of the cross-section of the product compared to a concentration of threads contained within the circumference. [6] The method according to claim 5, wherein the tool has a non-rectangular cross-section corresponding to a non-rectangular overall cross-section of the product. [7] The method according to claim 5 or claim 6, wherein the product is further defined as a cushioning pad. [8] The method according to claim 5 or claim 6, further comprising: Dispensing the molten thermoplastic resin using an arrangement of nozzles, which exceeds one area of ​​the opening, so that the molten thermoplastic resin engages in the leading edge. [9] The method of claim 8, further comprising: Dispensing the molten thermoplastic resin using an arrangement of nozzles, which exceeds the area of ​​the opening, up to three rows of nozzles within the arrangement. [10] The method according to claim 5 or claim 6, further comprising: Lubricating the leading edge before and / or during the application of the molten thermoplastic resin. [11] The method according to claim 10, further comprising: lubricating the leading edge with water. [12] The method according to claim 5 or claim 6, further comprising: Lubrication of a material that is moved along the leading edge before and / or during the delivery of the molten thermoplastic resin. [13] A product formed according to the method of claim 5 or claim 6. [14] The product according to claim 13, further comprising a seat cushion pad. [15] The method according to claim 5 or claim 6 further comprises: The attachment of the body as a padding cushion to a seating assembly. [16] A seat assembly manufactured according to the method of claim 15. [17] The method according to claim 5 or claim 6, further comprising the machining of the tool body. [18] The method according to claim 5 or claim 6, further comprising forming the tool from a metal alloy. [19] The method according to claim 5 or claim 6, further comprising the three-dimensional printing of the tool. [20] The method according to claim 5 or claim 6, further comprising forming the tool from a polymeric material. [21] A tool comprising a tool body with a through-hole and a leading edge around the opening, wherein the through-hole is dimensioned to fit the overall circumference of a product, wherein the leading edge and the through-hole are dimensioned to receive a molten thermoplastic resin in the form of a plurality of dispensed threads, wherein the through-hole of the tool is dimensioned to keep the plurality of dispensed threads within the overall circumference of the product. [22] The tool according to claim 21, wherein the through-hole of the tool is not rectangular in order to form the product with a non-rectangular cross-section. [23] The tool according to claim 21 or claim 22, wherein the through-opening of the tool is dimensioned to be the cross-section of a seat cushion pad. [24] The tool according to claim 21 or claim 22, wherein the tool body further comprises a plate. [25] An assembly comprising the tool according to claim 21 or claim 22, further comprising a material attached to the tool. [26] A system comprising: a thermoplastic resin extruder; the tool according to claim 21 or claim 22, which is oriented to receive dispensed thermoplastic resin from the extruder; and a fluid chamber oriented below the tool to receive the thermoplastic resin discharged from the tool, in order to cool the thermoplastic resin as the product.

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