Seat assembly, cushion, and assembly tool with instructive method

Abstract

To provide instructive method for forming non-foam cushion and related seat assembly and also its system and tools.SOLUTION: There is provided an instructive method including that a strand mesh material is inserted into the cavity of tool assembly which is made so as to form a cushion member. At a temperature higher than a first temperature threshold, fluid is circulated into the cavity through a series of openings demarcated on the formation surface of the tool assembly, thereby the material is softened, and the shape of the material is made to adapt to the formation surface. At a temperature lower than a second temperature threshold, the fluid is circulated into the cavity through a series of openings in the formation surface, thereby the shape of the material is arranged in the formation surface, and the cushion member is formed. By the strand mesh material member, the cushion of the seat assembly is provided. Thus, a system is provided which is equipped with the first tools, the second tools, and more than one entrance manifold.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] Various embodiments relate to tools and methods for forming non-foam cushions and associated seating assemblies, as well as non-foam cushions and seating assemblies. Summary of the Invention

[0002] The present invention provides a method, system and tool for forming a non-foam cushion and associated seating assembly, and also provides a non-foam cushion and seating assembly.

[0003] According to one aspect of the invention, a method is provided that includes inserting a strand mesh material feedstock into a cavity of a tool assembly to be shaped to form a cushioning member; circulating a fluid into the cavity through a series of openings defined on a forming surface of the tool assembly at a temperature above a first temperature threshold, thereby softening the feedstock and conforming the shape of the feedstock to the forming surface; and circulating a fluid into the cavity through a series of openings defined on the forming surface at a temperature below a second temperature threshold, thereby conforming the feedstock to the forming surface and forming the cushioning member.

[0004] In accordance with another aspect of the present invention, there is provided a cushion for a seating assembly comprising a strand mesh material member formed by the method described above.

[0005] According to another aspect of the invention, a system is provided that includes a first tool having a first forming surface and defining a first series of openings through the first forming surface, a second tool having a second forming surface configured to cooperate with the first forming surface to define a cavity and form a cushion member, and defining a second series of openings through the second forming surface, and an inlet manifold fluidly connected to the cavity via at least one of the first series of openings or the second series of openings.

[0006] According to another aspect of the invention, a system is provided that includes a first tool having a first forming surface and defining a first series of openings therethrough; a second tool having a second forming surface configured to cooperate with the first forming surface to define a cavity and form a cushion member and defining a second series of openings therethrough; one or more inlet manifolds; a fluid system including a fluid transfer device, a valve, and a heater in fluid communication with the inlet manifold; and a controller configured to control the valve to selectively fluidly couple the heater to the inlet manifold to provide fluid to the cavity at a first temperature and to selectively fluidly decouple the inlet manifold from the heater to provide fluid to the cavity at a second temperature that is lower than the first temperature. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a perspective view of a seat assembly according to an embodiment. [Diagram 2] 2 is a partial view of a cushion member according to one embodiment for use in the seat assembly of FIG. 1. [Diagram 3] FIG. 1 is a schematic diagram of a system according to one embodiment. [Figure 4] FIG. 4 is a perspective view of a first tool used in the system of FIG. 3. [Diagram 5] FIG. 4 is a perspective view of a second tool used in the system of FIG. 3. [Figure 6] 6 is another perspective view of the first tool of FIG. 4 or the second tool of FIG. 5. [Figure 7] FIG. 13 is a schematic top view of a system according to another embodiment in a closed position. [Figure 8] FIG. 8 is a schematic side view of the system of FIG. 7 in an open position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0009] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily drawn to scale, and some features may be exaggerated or minimized to show details of specific components. Therefore, 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 variously employ the embodiments according to the present disclosure.

[0010] "One or more" includes a function being performed by a single element, a function being performed by two or more elements, e.g., in a distributed manner, multiple functions being performed by a single element, multiple functions being performed by multiple elements, or any combination of the above.

[0011] Also, although terms such as first, second, etc. are used in some instances herein to describe various elements, it will be understood that these elements should not be limited by these terms. These terms are merely used to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact, without departing from the scope of the various described embodiments. A first contact and a second contact are both contacts, but are not the same contact.

[0012] The terms used in the description of the various described embodiments herein are for the purpose of describing particular embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It will also be understood that the term "and / or" as used herein is used to refer to and include any and all possible combinations of one or more of the associated listed items. Furthermore, it will be understood that the terms "comprising" or "including" as used herein specify the presence of stated 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.

[0013] As used herein, the term "when" is interpreted to mean "when," or "upon," or "in response to determining," or "in response to detecting," optionally depending on the context. Similarly, the phrases "when determined" or "when [specified condition or event] is detected" are interpreted to mean "upon determining," or "in response to determining," or "upon detecting [specified condition or event]," optionally depending on the context.

[0014] The term controller may be provided as one or more controllers or control modules for various components and systems. The controllers and control systems may include any number of controllers, may be integrated into a single controller, or may have various modules. Some or all of the controllers may be connected by a controller area network (CAN) or other system. It is recognized that any controller, circuit, or other electrical device disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., flash memory, random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variants) and software that cooperate with each other to perform the operation(s) disclosed herein. In addition, any one or more of the electrical devices disclosed herein may be configured to execute a computer program embodied in a non-transitory computer-readable medium that is programmed to perform any number of functions disclosed herein.

[0015] Referring to FIG. 1, a seat assembly 20 is shown, such as a vehicle seat assembly 20. In other examples, the seat assembly 20 may be shaped and sized as a front row driver or passenger seat, a second row seat, a third row seat, or other rear row seat, and may include a bench-style seat as shown, a bucket seat, or other seat styles. Further, the seat assembly may be a non-retractable seat, or a retractable seat that may be foldable and retractable into a cavity in the floor of the vehicle. Additionally, the seat assembly 20 may be used in other non-vehicle applications.

[0016] The seat assembly 20 includes a frame 22 or other support structure. The seat assembly includes seat components including at least a seat bottom 24 and a seat back 26. The seat bottom 24 may be sized to receive a seated occupant and support the occupant's pelvis and thighs. The seat back 26 may be sized to extend upright from the seat bottom 24 and support the occupant's back. The seat assembly may additionally include a head rest 27, only the head rest 27 of the adjacent seat assembly is shown. The seat bottom 24 includes a seat bottom cushion 28. The seat back 26 includes a seat back cushion 30. The frame 22 may include a wire suspension mat or other structure that supports the cushions 28, 30.

[0017] The frame 22 provides rigid structural support for the seat components, e.g., the seat bottom 24 and the seat back 26, and may be provided as a plurality of frame members that are movable relative to one another to provide adjustment of the seat assembly. The frame may be formed from stamped steel alloy, fiber reinforced polymer, or any suitable structural material. The frame 22 may further comprise a substrate, e.g., a panel, that supports an associated cushion.

[0018] One or more trim covers 32 are used to cover the seat bottom cushion 28 and the seat back cushion 30 and provide a seating surface for the seat assembly 20. The vehicle seat assembly 20 is shown without the trim cover, and the trim cover 32 is shown on an adjacent seat assembly. In one example, the trim cover 32 covers both the cushions 28, 30. In another example, multiple trim covers are provided to cover the seat bottom and seat back cushions. The trim cover 32 may be formed from one or more panels of fabric, leather, artificial leather, vinyl, or other material.

[0019] The seat cushion 40 is described in more detail below, but the description is equally applicable to the seat bottom cushion 28 or the seat back cushion 30. The seat cushion 40 described herein may additionally be used in other seat components, or other interior vehicle components.

[0020] In the illustrated example, the seat cushion 40 includes at least one non-foamed component or member 42. In one example, as illustrated, the seat cushion 40 is formed solely from the non-foamed component 42, which provides all of the cushioning of the seat component between the frame 22 and the trim cover 32. In other examples, the seat cushion 40 can be formed from the non-foamed component 42 and one or more foamed components, such as a component comprised of molded polyurethane foam, or other non-foamed components. The seat cushion 40 can have non-foamed and foamed components positioned to provide different regions of the cushion 40 of the seat component, for example, a center region and side bolster regions. By removing some or all of the conventional foam from the seat cushion 40, the seat assembly 20 can be provided with improved support and comfort, as well as weight savings.

[0021] In one non-limiting example, the non-foamed components or members 42 of the seat cushion 40 are formed by a strand mesh material, also known as an intertwined three-dimensional filament structure. The strand mesh material is made of a polymer mesh having a plurality of integrated polymer strands. The strand mesh material can be made, for example, from a linear low density polyethylene (LLPDE) material, although other polymers and materials are contemplated that are effective to provide the desired properties and functionality. The strand mesh material can be formed using extruded filaments of linear low density polyethylene (LLDPE) that are randomly intertwined, bent, looped, or otherwise positioned and oriented and directly bonded to each other to provide a porous mesh structure. An example is shown in the expanded view of FIG. 2.

[0022] 2, the cushion may be formed from a cushion stock 41 or strand mesh material member 42 having a first side 44 and a second side 46 located opposite the first side 44. A side surface 47 or edge extends between the first side 44 and the second side 46. The first side 44 may be positioned on the seat assembly 20 to support an occupant of the seat assembly. The various sides 44, 46, 47 may be formed from the cushion stock via a system described below and may include various features such as recesses, grooves, channels, concave or convex surfaces, or other contours on the sides 44, 46, 47 or at the intersections of associated sides 44, 46, 47. The cushion stock 41 may include one or more slits 48 or cuts in the cushion stock 41 that are used in a system described below to form various features or shapes in the cushion 40 from the stock 41.

[0023] The cushion material 41 can be formed from an interlocking filament structure that provides the strand mesh material that forms the cushion 40 and member 42 described above. Raw material, such as solid granules or pellets of plastic, such as linear low density polyethylene (LLDPE), can be fed from a hopper to an extruder. The extruder melts the raw material and conveys it through a die plate. The material leaves the extruder in a molten state under pressure. The die plate extrudes the material into filaments through a number of small circular through holes or apertures through which the molten material passes, with a single filament being extruded from each die plate hole. The filaments fall from the die plate into a funnel that serves to connect or group the filaments, causing them to bend or loop, with each filament contacting and adhering to at least one other filament into a more compact configuration. The interlocking filament structure then enters a fluid bath, such as a liquid tank, that serves to temporarily support the interlocking filament structure, maintain porosity and density, and externally cool and solidify the filaments. The tank can be equipped with various rollers and conveyors, and the connected filament structure can be cut, for example, using a cut-off wheel, water jet, or another technique, into the desired size and shape to form the cushioning material. In one non-limiting example, the cushioning material 41 is provided as a generally rectangular prism.

[0024] The cushion material 41 may be further cut to form one or more slots or slits 48 prior to use in the system described below. The cushion material 41 may be cut to a blind hole depth, i.e., partially through the material 41, to form the slots 48. The cushion material 41 may be further cut to a near net shape based on the desired shape and size of the cushion 40 and the desired localized density characteristics of the cushion 40.

[0025] 3 illustrates a system 100 for forming the cushion 40 from the cushion material 41. The cushion material 41 is positioned in the system 100 to form the cushion material 41 into the desired final shape of the cushion 40 with features, e.g., recesses, contours, etc. The cushion material 41 is formed from an interlocking filament structure as described above after cooling the material and cutting it into a blank form.

[0026] The system 100 includes a tool assembly 102. The tool assembly 102 is in fluid communication with one or more fluid systems 104. Each fluid system 104 includes a fluid transfer device 106, such as a pump or fan, one or more valves 108, and a heater 110. The fluid systems 104 may provide a flow of pressurized gas, such as air, or liquid to the tool assembly 102 using a flow controller via a controller 112. In the illustrated non-limiting example, the fluid system(s) 104 provide air to the tool assembly 102.

[0027] 3-6, the tool assembly 102 of the system 100 includes a first tool 120 and a second tool 140. The first tool 120 includes a first forming surface 122 that defines a series of first openings 124 extending therethrough. The second tool 140 includes a second forming surface 142. In one non-limiting example, the second forming surface 142 defines a series of second openings 144 extending therethrough. The first forming surface 122 and the second forming surface 142 cooperate to define a cavity 160 that is molded to form the cushion member from the material 41. The cavity 160 is molded to form a variety of shapes, including concave, convex, or other complex shapes, channels, recesses, curves, chamfers, stepped corners or areas, and the like, from the material 41 to the cushion 40. Additionally, the cavity 160 can be sized to be smaller in volume than the material 41 such that the tooling assembly 102 compresses the material 41 within the tooling assembly, thereby providing different localized densities within different regions within the cushion 40. In other words, the material 41 can be sized larger than the cavity 160. The resulting variation in localized density within the cushion 40 can be advantageous, for example, by providing increased density in thinner portions or regions.

[0028] Collectively, the first tool 120 and the second tool 140 define a portion of the openings 124, 144 in the forming surfaces 122, 142 of the tooling assemblies, respectively. Although the openings 124, 144 in the first tool and the second tool, respectively, are shown as circular, the openings can have other cross-sectional shapes. The openings 124, 144 can have a common diameter or can have different diameters, for example, to better control the flow of the cushioning material 41 to different areas within the tooling assembly 102. The openings 124, 144 can additionally be approximately equally spaced from one another on the forming surfaces, or the spacing between the openings can vary to similarly control the flow of the cushioning material 41 to different areas within the tooling assembly 102. In various examples, there can be certain areas of the forming surfaces 122, 142 that are provided without openings.

[0029] The first tool 120 has a mating surface 126 that cooperates with a corresponding mating surface 146 of the second tool 140 when the tool assembly 102 is closed. The first tool 120 can be translated or otherwise moved toward and away from the second tool 140 to open and close the tool assembly.

[0030] In the illustrated example, the tool assembly 102 has a first fluid system 104a and a second fluid system 104b. Although the first fluid system 104a and the second fluid system 104b are illustrated and described as being distinct from one another, in other examples, two fluid systems 104a, two fluid systems 104b, or a single fluid system 104a, 104b may be used.

[0031] The first fluid system 104a includes a fluid transfer device 106a selectively connected to a heater 110a via a valve 108. The controller 112 controls the position of the valve 108 and the operation of the heater 110a to provide fluid to the first inlet manifold 114a and the first tool 120, as described below. The first inlet manifold 114a may further include a valve 108 that selectively controls flow through each of the lines of the manifold 114a, for example, by controlling the flow rate. The inlet manifold 114a is fluidly connected to the first tool 120 and the cavity 160 via a series of first openings 124. The fluid system 104a is fluidly connected to the tool assembly 102 via the inlet manifold 114a. The inlet manifold 114a may provide two or more inlet ports into the first tool 120 as shown, or may provide a single inlet.

[0032] The second fluid system 104b has two fluid transfer devices 106b. One fluid transfer device 106b is connected to a heater 110b, which is connected to an inlet manifold 114b via a valve 108. The other fluid transfer device 106b is connected to the inlet manifold 114b by another valve 108. The controller 112 controls the position of the valve 108, the fluid transfer devices 106b, and the heater 110b to provide fluid to the first inlet manifold 114b and the second tool 140, as described below. The first inlet manifold 114a can further include a valve 108 to selectively control flow through each of the lines of the manifold 114a, for example, by controlling the flow rate. The inlet manifold 114a is fluidly connected to the first tool 120 and the cavity 160 via a series of first openings 124. The fluid system 104a is fluidly connected to the tool assembly 102 via an inlet manifold 114a. The inlet manifold 114a may provide two or more inlet ports into the first tool 120 as shown, or may provide a single inlet.

[0033] In further examples, various functions of the fluid systems 104a, 104b may be combined, for example, using a single controller 112, or by using a single fluid transfer device and / or heater to provide fluid flow to both manifolds 114a, 114, etc.

[0034] The interiors of the first tool 120 and the second tool 140 may each define one or more chambers facing the forming surfaces 122, 142, with associated openings 124, 144 connecting the forming surfaces to the respective chamber(s). FIG. 6 shows a view of the second tool 140 facing the forming surface 142, with the tool 140 having four chambers 150 separated by internal support walls 152. The internal support walls 152 provide structural support for the forming surface 142 and may also separate the flow streams to maintain or control flow uniformity. In other examples, openings 154 may be provided in the support walls 152 as shown to provide cross flow between the chambers 150.

[0035] The first tool 120 can be configured similarly to the second tool 140, where one or more support walls 152 define multiple chambers 150. An inlet manifold 114, such as manifolds 114a, 114b, can provide one or more inlet ports associated with each chamber 150 within the first tool and / or second tool 140. Thus, flow to different chambers 150 within the first tool and / or second tool 140, as well as to different regions of the cavity 160 and material 41, can be similarly controlled.

[0036] In addition to the support walls 152, the chambers 150 in the first tool and second tool can support various flow deflectors, baffles, and other features that control the flow direction through the material 41 into and out of the cavity 160.

[0037] In the illustrated example, the tool assembly 102 is provided with one or more outlets 116 formed in the first tool 120, the second tool 140, or both tools 120, 140. The outlets 116 can fluidly connect the cavity 160 to the atmosphere directly through the cavity 160 or through one of the chambers 150 to vent the cavity 160 if the fluid in the system 104 is air, or can be connected to a return line to the fluid system(s) 104a, 104b in the case of a closed system. The outlets 116 can be provided with a closure member 117, such as a baffle, plate member, or valve. The closure member 117 can be further controlled, for example by the controller 112, between an open position to vent the cavity and a closed position to hold or maintain the fluid in the cavity 160. In various examples, the closure member 117 can be opened and closed during operation of the fluid transfer device 106 and / or heater 110, for example, to provide a desired temperature profile within the cavity 160. In other examples, the tool assembly 102 is provided without a closure member 117 such that the outlet(s) 116 are non-closable. In further examples, the tool assembly 102 is provided without a defined outlet port 116, and the tool assembly 102 can be vented through various gaps or spacings between the mating surfaces 126, 146. Fluid flows from each fluid system 104a, 104b, into the respective inlet manifolds 114a, 114b, into the cavity 160, and then to the outlet(s) 116.

[0038] In a further example, the tool assembly 102 is provided with a single fluid system 114a or 114b instead of the other inlet manifolds 114b, 114a, and a single outlet 116, with fluid flowing sequentially from one inlet manifold, through both tools 120, 140, and to the outlet 116. Fluid may flow sequentially within the assembly 102 from the inlet manifold 114, through the chamber 150 in the first tool 120, through the first series of openings 124, through the cavity 160 and the blank 41, through the second series of openings 144, into the chamber 150 in the second tool 140, and to the outlet 116. As will be described below, the fluid may be at various temperatures to control the shaping of the blank 41.

[0039] When material 41 is formed from a strand mesh material and is porous, the flow of fluid entering inlet manifold 114 flows through a first series of openings 124 in the first tool, through the strand mesh material of material 41, through a second series of openings 144 in the second tool, and to outlet 116. Thus, the fluid convectively heats or cools the filaments and strands in the interior of material 41, as well as the strands along the exterior surface of material 41.

[0040] The first tool 120 and / or the second tool 140 may be provided with one or more positioning members 170 extending outwardly from their respective forming surfaces 122, 142. In the illustrated example, the second tool 140 is provided with a plurality of positioning members 170 as pins. The positioning features 170 may be used to position and hold the feedstock 41 in a desired location on the tool before and during closure of the tool assembly. When the feedstock 41 is a filament structure, the pins 170 may easily extend between the filaments in the feedstock 41 when positioning the feedstock on the tool. In a further example, the positioning pins 170 may be optionally retractable such that they retract when the tool assembly is open to facilitate removal of the cushion 40.

[0041] The forming surface 122 and / or the forming surface 142 may include one or more protrusions 180 to form corresponding channels, recesses, pockets, or other recessed areas in the cushion 40 from the blank 41. Depending on the geometry of the protrusions 180, the blank 41 may be cut at locations corresponding to the protrusions before the blank is inserted into the tooling assembly. For example, when a channel is formed, a blind hole cut or slit 48 may be cut in the blank 41 to provide a relief adjacent the channel in the resulting cushion 40 to reduce gaps, warping, or distortion. Similarly, when a recessed area is formed, a blind hole cut or slit 48 may be cut in the blank 41 along the periphery of the recess to provide a relief adjacent the recess in the resulting cushion 40 to reduce gaps or warping when the protruding forming surface 180 pushes the blank material in the recessed area. In other examples, other types of cuts may be provided, such as planar cuts, curved cuts, or cuts of another complex geometry as a portion of a through cut or partial cut into the blank 41. These protrusions 180 may further provide positioning features or members for the tool assembly 102 .

[0042] The system 100 also includes a controller 112. The controller 112 is configured to control the fluid transfer device(s) 106, the valve 108, and the heater(s) 110 to selectively fluidly couple the heater 110 to the inlet manifold 114 to provide fluid to the cavity 160 at a first temperature, and to selectively fluidly decouple the inlet manifold 114 from the heater 110 to provide fluid to the cavity 160 at a second temperature, lower than the first temperature. If the tool assembly 102 includes an outlet closure member 117, the controller 112 can control a position of the closure member 117 to retain fluid in the cavity 160 or to vent the cavity. For example, the controller 112 can close the closure member 117 when providing fluid at the first temperature and open the closure member 117 when providing fluid at the second temperature, or vice versa. Additionally, the controller 112 can at least partially open or at least partially close the closure member 117 while providing the fluid at the first temperature and / or the second temperature to control the temperature profile within the cavity 160. The system 100 can have various sensors, such as temperature sensors, used in controlling the flow through the tooling assembly 102. The first temperature and the second temperature can be set based on a softening temperature of the material of the filament of the feedstock 41. In one example, the first temperature is set at a temperature offset above the softening temperature, for example, 20°C to 30°C above the softening temperature. In another example, the second temperature is set at a temperature offset below the softening temperature and can be provided at ambient temperature. The controller 112 can further control the time for providing the fluid into the cavity 160 at the first temperature, the time for providing the fluid into the cavity 160 at the second temperature, the flow rate of the fluid, and / or the rise in temperature of the fluid to further control the forming process of the feedstock 41. The controller 112 can additionally control the valves 108 on the individual lines in the inlet manifold 114 to control flow to different areas of the various chambers 150 and cavities 160 within the tools 120 , 140 .

[0043] The softening temperature refers to the glass transition temperature of the material, which can be a temperature below the melting point, allowing the filaments to soften and change shape as well as the material 41 without completely melting the filaments and losing the overall filament structure and porosity within the material 41 and the resulting cushion.

[0044] In various examples, a method for forming a cushion 40 from a cushion material 41 or strand mesh material material 41 is provided that can be used with the system 100 and controller 112. In a first step, the material is inserted into a cavity 160 of the tool assembly 102 that is shaped to form a cushion member. After inserting the material into the cavity, the first tool 120 is moved relative to a second tool 140 of the tool assembly to close the tool assembly with the material therein. The material 41 can be compressed by the first tool 120 and the second tool 140 because the size of the material 41 can be larger than the cavity 160, e.g., the volume of the material can be larger than the volume of the cavity. In various examples, the material 41 can be compressed to different degrees in different areas based on the size and shape of the material 41 relative to the size and shape of the cavity 160.

[0045] If slot(s) 48 have been cut into the blank 41, the forming surface protrusions 180 are inserted into the blank slots as the blank is inserted into the cavity 160 of the tool assembly.

[0046] It should be noted that the tools 120, 140 can be preheated before the material 41 is inserted into the tool assembly, or heating of the tools 120, 140 can be achieved via flow of fluid at a first temperature only after the material 41 is inserted.

[0047] In a second step, the controller 112 operates the fluid transfer device(s) 106, valve 108, and heater(s) 110 to circulate fluid at a temperature above a first temperature threshold into the inlet manifold 114 and through a series of openings 124 defined in the forming surface 122 of the tooling assembly into the cavity 160, thereby softening the blank 41 and conforming the blank to the forming surfaces 122, 142. The controller 112 can further control the closure member 117, for example, to a closed position that generally retains the fluid within the cavity 160 and / or an open position that vents the cavity 160.

[0048] In a third step, the controller 112 then controls the fluid transfer device 106, the valve 108, and the heater 110 to circulate the fluid at a temperature below the second temperature threshold through the series of openings 124 in the forming surface 122 into the cavity 160, thereby shaping the material 41 to the forming surface 122, 142 and forming the cushion member. In various examples, the first temperature threshold is above a softening temperature of the material 41 and the second temperature threshold is below a softening temperature of the material 41. In further examples, the fluid can be provided to the tool assembly at ambient temperature during the third step. The controller 112 can further control the closure member 117, for example, to an open position that generally vents the fluid in the cavity 160 and / or a closed position.

[0049] The second step can be a first temperature cycle to soften and form the material 41 into the shape defined by the forming surface, and the third step can be a second temperature cycle to shape the material into the shape of the material 41. In various examples, the first step, second step, and third step can occur sequentially.

[0050] 7 and 8, a tool assembly 200 according to another embodiment is shown generally in FIG. 3 in place of tool assembly 102 and generally in accordance with the methods described above. Elements that are the same or similar to those described above may not be described with respect to FIG. 7 and 8 for simplicity. FIG. 7 shows a schematic top view of tool assembly 200 and FIG. 8 shows a schematic side view of tool assembly 200 in an open position.

[0051] The tool assembly 200 includes a first tool 220 and a second tool 240. The first tool 220 and the second tool 240 are each positioned within a central region of a common chamber 202. Each of the first tool 220 and the second tool 240 may be supported by a post or other support member 204 within the chamber 202. The first tool 220 has a first forming surface 222 that defines a series of first openings 224 therethrough. The second tool 240 has a second forming surface 242 that defines a series of second openings 244 therethrough. The first forming surface 222 and the second forming surface 242 cooperate to define a cavity 260 that is shaped to form a cushion from the cushioning material 41. The first tool 220 has a mating surface 226 that connects with a corresponding mating surface 246 of the second tool when the tool assembly 200 is closed. The first tool 220 can be translated or otherwise moved toward and away from the second tool 240 to open and close the tool assembly.

[0052] The chamber 202 has at least one inlet 206 in fluid communication with a circumferential inlet manifold 208 that is in fluid communication with a fluid system, such as fluid system 104a or 104b. The inlet manifold 208 extends around or along at least a portion of the circumference of the chamber 202. The inlet(s) 206 from the inlet manifold 208 to the chamber 202 are provided along the outer periphery wall of the chamber. The circumferential inlet manifold 208 may receive fluid from the inlet manifold 114 via ports 210 or may be part of an inlet manifold. In the illustrated example, the chamber has a single inlet 206, although other numbers of inlets 206 are envisioned. The circumferential inlet manifold 208 may receive flow from a single port 210 or from multiple ports 210 as shown. The inlets 206 may have associated deflectors 212. The deflectors may extend at an angle into the circumferential inlet manifold 208 to help direct the flow from the manifold 208 at a desired flow angle. The inlets 206 may further be formed with walls that are angled relative to the adjacent circumferential flow manifold 208 and relative to the flow direction of the fluid therein, as shown in FIG. 7. In one non-limiting example, the angle of the deflectors 212 and inlets 206 is 45 degrees, although other acute angles are contemplated. Although only one inlet 206 is shown, multiple inlets 206 and deflectors are contemplated, with the inlets 206 spaced apart along the circumferential manifold 208 to aid in the creation of vortex or circular flow within the chamber 202.

[0053] The chamber 202 also defines an outlet 214. The outlet 214 is positioned to fluidly connect a central region of the chamber 202 to the atmosphere such that fluid circulates within the chamber 202 radially inward from the inlet(s) 206 around the periphery of the chamber 202 (and from the circumferential inlet manifold 208) to the outlet 214. This generally provides a vortex flow geometry within the chamber 202.

[0054] The tooling assembly 200 may be positioned within the system 100 and controlled via the controller 112 according to the methods described above. According to various examples, the fluid sequentially flows within the assembly 102 from the inlet manifold 114, the circumferential manifold 208, through the inlet 206 into the chamber 202, and then has a vortex or circular flow path toward the tools 220, 240. The fluid flows through the openings 224, 244 in the tools 220, 240, through the cavity 160 and the blank 41, and to the outlet 214. As described above, the fluid may be at various temperatures to control the shaping of the blank 41.

[0055] When material 41 is formed from a strand mesh material and is porous, fluid flowing into inlet manifold 114 flows through a first series of openings 124 in the first tool, through the strand mesh material of material 41, through a second series of openings 144 in the second tool, and to outlet 116. Thus, the fluid convectively heats or cools the filaments and strands in the interior of material 41, as well as the strands along the exterior surface of material 41.

[0056] Clause 1. A method is provided comprising inserting a strand mesh material feedstock into a cavity of a tool assembly shaped to form a cushioning member, circulating a fluid at a temperature above a first temperature threshold into the cavity through a series of openings defined in a forming surface of the tool assembly, thereby softening the feedstock and conforming the shape of the feedstock to the forming surface, and circulating a fluid at a temperature below a second temperature threshold into the cavity through a series of openings defined in the forming surface, thereby conforming the feedstock to the forming surface and forming a cushioning member.

[0057] Clause 2. The method of clause 1, further comprising moving a first tool of the tool assembly relative to a second tool of the tool assembly after inserting the strand mesh material blank into the cavity.

[0058] Clause 3. The method of clause 2, wherein a first tool defines a first portion of the series of apertures and a second tool defines a second portion of the series of apertures.

[0059] Clause 4. The method of clause 2, further comprising compressing the strand mesh material feed by moving the first tool relative to the second tool.

[0060] Clause 5. The method of any one of clauses 1-4, further comprising cutting a slot in the strand mesh material blank to a blind hole depth prior to inserting the blank into the cavity of the tool assembly, and inserting a protrusion of the forming surface into the slot in the blank as the blank is inserted into the cavity of the tool assembly.

[0061] Clause 6. The method of any one of clauses 1-5, wherein the first temperature threshold is greater than a softening temperature of the material and the second temperature threshold is less than a softening temperature of the material.

[0062] Clause 7. The method of any one of clauses 1-6, further comprising forming the strand mesh material as a polymer mesh having a plurality of integral polymer strands.

[0063] Clause 8. The method of clause 7, further comprising forming a strand mesh material blank by extruding the material through a die, passing the extruded material from the die through a funnel, and moving the extruded material after passing through the funnel through one or more rollers, and cutting the strand mesh material blank after forming the blank and prior to inserting the blank into the cavity of the tool assembly.

[0064] Clause 9. A cushion for a seat assembly comprising a strand mesh material member formed by the method of clause 8.

[0065] Clause 10. A system is provided that includes a first tool having a first forming surface and defining a first series of openings therethrough, and a second tool having a second forming surface configured to cooperate with the first forming surface to define a cavity and form a cushion member, the second tool defining a second series of openings therethrough. An inlet manifold is fluidly connected to the cavity via at least one of the first series of openings or the second series of openings.

[0066] Clause 11. The system of clause 10, wherein the first tool defines one or more first chambers in fluid communication with the inlet manifold, the one or more first chambers in fluid communication with the cavity via a series of first openings in the first forming surface.

[0067] Clause 12. The system of clause 10 or 11, wherein the inlet manifold is a first inlet manifold, the first inlet manifold supported by the first tool and fluidly connected to the cavity via a series of first openings, and the system further comprises a second inlet manifold, the second inlet manifold supported by the second tool and fluidly connected to the cavity via a series of second openings.

[0068] Clause 13. The system of any one of clauses 10-12, further comprising an outlet fluidly coupled to the inlet manifold via the series of first openings and cavities.

[0069] Clause 14. The system of clause 13, wherein the outlet is at least partially defined by one or more outlet ports in at least one of the first tool or the second tool, each of the one or more outlet ports comprising a closure member movable between an open position and a closed position.

[0070] Clause 15. The system of clause 13, wherein the first tool and the second tool are positioned within a central region of a chamber, the chamber having at least one inlet in fluid communication with an inlet manifold and defining an outlet.

[0071] Clause 16. The system of clause 15, wherein the inlet manifold extends along at least a portion of an outer peripheral wall of the chamber, the inlet being positioned along the outer peripheral wall of the chamber, and the outlet being positioned to fluidly connect a central region of the chamber to the atmosphere such that fluid circulates radially inward within the chamber from the inlet to the outlet.

[0072] Clause 17. The system of clause 16, wherein the inlet further comprises a deflector, the deflector extending into the inlet manifold and positioned to direct the fluid into the chamber.

[0073] Clause 18. The system of any one of clauses 10-17, further comprising one or more positioning members extending outwardly from the first forming surface and / or the second forming surface.

[0074] Clause 19. The system of any one of clauses 10-18, further comprising a fluid transfer device, a heater, and a valve in fluid communication with the inlet manifold, and a controller. The controller is configured to control the valve to selectively fluidly couple the heater to the inlet manifold to provide fluid to the cavity at a first temperature, and to selectively fluidly decouple the inlet manifold from the heater to provide fluid to the cavity at a second temperature, the second temperature being lower than the first temperature.

[0075] Clause 20. A system is provided that includes a first tool having a first forming surface and defining a first series of openings therethrough, and a second tool having a second forming surface configured to cooperate with the first forming surface to define a cavity and form a cushion member and defining a second series of openings therethrough. One or more inlet manifolds are provided. A fluid system is provided with a fluid transfer device, a valve, and a heater in fluid communication with the inlet manifold. A controller is configured to control the valve to selectively fluidly couple the heater to the inlet manifold to provide fluid to the cavity at a first temperature and to selectively fluidly decouple the inlet manifold from the heater to provide fluid to the cavity at a second temperature lower than the first temperature.

[0076] Clause 21. Any one of clauses 1 to 20 above in any combination.

[0077] Although exemplary embodiments have been described above, it is not intended that these embodiments represent all possible forms according to the present disclosure. In that regard, it is understood that the words used herein are words of description rather than of limitation, and that various changes can be made without departing from the spirit and scope of the present disclosure. In addition, features of various embodiments can be combined to form further embodiments according to the present disclosure.

[0078] This application claims the benefit of U.S. Patent Application No. 18 / 178,818, filed March 6, 2023, the disclosure of which is incorporated herein by reference in its entirety.

Claims

1. a first tool having a first forming surface and defining a series of first openings through said first forming surface; a second tool including a second forming surface configured to cooperate with the first forming surface to define a cavity and form a cushion member, the second forming surface defining a series of second openings therethrough; an inlet manifold fluidly connected to the cavity via at least one of the first series of openings or the second series of openings; Equipped with The system further comprises an inlet manifold extending along an outer peripheral wall of a chamber formed by the first tool and the second tool, the chamber having at least one inlet in fluid communication with the inlet manifold, the at least one inlet having a deflector positioned to extend into the inlet manifold at a predetermined angle relative to the inlet, whereby the deflector is adapted to direct fluid into the chamber.

2. 2. The system of claim 1, wherein the first tool defines one or more first chambers in fluid communication with the inlet manifold, the one or more first chambers in fluid communication with the cavity via the series of first openings in the first forming surface.

3. the inlet manifold is a first inlet manifold, the first inlet manifold being supported by the first tool and fluidly connected to the cavity through the first series of openings; 2. The system of claim 1, further comprising a second inlet manifold supported by the second tool and fluidly connected to the cavity via the series of second openings.

4. The system of claim 1 , further comprising an outlet fluidly coupled to the inlet manifold through the first series of openings and the cavity.

5. 5. The system of claim 4, wherein the outlet is at least partially defined by one or more outlet ports in at least one of the first tool or the second tool, each of the one or more outlet ports comprising one of a baffle, a plate member, or a valve movable between an open position and a closed position.

6. The system of claim 4 , wherein the first tool and the second tool are positioned within a central region of a chamber, the chamber defining the outlet.

7. 7. The system of claim 6, wherein the at least one inlet is positioned along the outer peripheral wall of the chamber and the outlet is positioned to fluidly connect the central region of the chamber to the atmosphere such that fluid circulates radially inward within the chamber from the at least one inlet to the outlet.

8. The system of claim 1 , further comprising one or more members extending outwardly from the first forming surface and / or the second forming surface.

9. 2. The system of claim 1, further comprising a fluid transfer device, a heater, and a valve in fluid communication with the inlet manifold, the controller configured to control the valve to selectively fluidly couple the heater to the inlet manifold to provide fluid to the cavity at a first temperature and to selectively fluidly decouple the inlet manifold from the heater to provide fluid to the cavity at a second temperature lower than the first temperature.

10. a first tool having a first forming surface and defining a series of first openings through said first forming surface; a second tool including a second forming surface configured to cooperate with the first forming surface to define a cavity and form a cushion member, the second forming surface defining a series of second openings therethrough; one or more inlet manifolds; a fluid system including a fluid transfer device, a valve, and a heater in fluid communication with the one or more inlet manifolds; a controller configured to control the valves to selectively fluidly couple the heater to the one or more inlet manifolds to provide fluid to the cavity at a first temperature and to selectively fluidly decouple the one or more inlet manifolds from the heater to provide fluid to the cavity at a second temperature lower than the first temperature; Equipped with The system further comprises one or more inlet manifolds extending along an outer peripheral wall of a chamber formed by the first tool and the second tool, the chamber having at least one inlet in fluid communication with the inlet manifold, the at least one inlet having a deflector positioned to extend into the inlet manifold at a predetermined angle relative to the inlet, whereby the deflector is adapted to direct fluid into the chamber.

11. The system of claim 1 , wherein at least a portion of the cushioning member is formed from a non-foam component.

12. 11. The system of claim 10, wherein the first tool defines one or more first chambers in fluid communication with the one or more inlet manifolds, the one or more first chambers in fluid communication with the cavity via the series of first openings in the first forming surface.

13. one of the one or more inlet manifolds is a first inlet manifold, the first inlet manifold supported by the first tool and fluidly connected to the cavity via the series of first openings; 11. The system of claim 10, further comprising a second inlet manifold of the one or more inlet manifolds, the second inlet manifold supported by the second tool and fluidly connected to the cavity via the second series of openings.

14. The system of claim 1 , further comprising an outlet fluidly coupled to the one or more inlet manifolds via the first series of openings and the cavity.

15. 15. The system of claim 14, wherein the outlet is at least partially defined by one or more outlet ports in at least one of the first tool or the second tool, each of the one or more outlet ports comprising one of a baffle, a plate member, or a valve movable between an open position and a closed position.

16. The system of claim 14 , wherein the first tool and the second tool are positioned within a central region of a chamber, the chamber defining the outlet.

17. 17. The system of claim 16, wherein the at least one inlet is positioned along the outer circumferential wall of the chamber and the outlet is positioned to fluidly connect the central region of the chamber to the atmosphere such that fluid circulates radially inward within the chamber from the at least one inlet to the outlet.

18. The system of claim 10 , further comprising one or more members extending outwardly from the first forming surface and / or the second forming surface.

19. 11. The system of claim 10, wherein the first series of openings are equally spaced from one another on the first forming surface and the second series of openings are equally spaced from one another on the second forming surface.

20. The system of claim 1 , wherein the deflector extends into the inlet manifold at an angle relative to the inlet manifold.

21. The system of claim 1 , wherein the at least one inlet has an angled wall relative to the inlet manifold.

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