Tool with integrated fluid lines to form cushion assembly

Abstract

To provide a seat assembly.SOLUTION: A product is provided with a body with a nonrectangular cross section with a mesh of strands of expanded thermoplastic resin. A density of the mesh of strands about a perimeter of the nonrectangular cross section is greater than within the perimeter. The perimeter is provided with at least one recess formed therein.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Patent Application No. 18 / 390,516, filed on December 20, 2023, and Danish Patent Application No. PA202470199, filed on July 30, 2024, the disclosures of which are hereby incorporated by reference in their entirety.

[0002] Various embodiments relate to a cushion assembly for a seat assembly.

Summary of the Invention

[0003] According to one aspect of the present invention, there is provided a product comprising a body having a non - rectangular cross - section including a strand mesh of a foamed thermoplastic resin, wherein the density of the strand mesh around the periphery of the non - rectangular cross - section is greater than that inside the periphery, and the periphery has at least one recess formed therein.

[0004] According to another aspect of the present invention, there is provided a method of manufacturing a product, comprising: extruding a plurality of strands of molten thermoplastic resin through a tool having an opening sized to conform to the overall cross - section of the product; engaging the tip of the tool with a plurality of outer strands of the molten thermoplastic resin; passing the plurality of strands of the molten thermoplastic resin through the opening; passing a plurality of inner strands of the molten thermoplastic resin through the opening at an interval inside the tip; extruding fluid through a fluid line formed through the tool; and the like.

[0005] According to another aspect of the present invention, there is provided a tool having a tool body with a through-opening and a tip portion around the opening, wherein the through-opening is sized to fit the overall periphery of the product, the tip portion and the through-opening are sized to receive molten thermoplastic resin as a plurality of extruded strands, the tool through-opening is sized to maintain the plurality of extruded strands inside the overall periphery of the product, and a fluid line for cooling the tool and the plurality of strands is formed through the tool.

Brief Description of the Drawings

[0006]

Figure 1

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Modes for Carrying Out the Invention

[0007] Next, refer to the embodiments in detail. Examples thereof are shown in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments can 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 obscure aspects of the embodiments needlessly.

[0008] It should be understood that the disclosed embodiments are merely exemplary and that various alternatives are possible. The drawings are not necessarily drawn to an exact scale, and some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as a representative basis for those skilled in the art to variously adopt embodiments according to the present disclosure.

[0009] "One or more" includes that a function is performed by one element, that a function is performed by two or more elements in a distributed manner, for example, that multiple functions are performed by one element, that multiple functions are performed by multiple elements, or any combination of the above.

[0010] Also, terms such as first, second, etc. are used herein in some instances to describe various elements, but it will be understood that these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first surface may be referred to as the second surface, and similarly, the second surface may be referred to as the first surface. The first surface and the second surface are both surfaces, but not the same surface.

[0011] In the description of the embodiments of the various descriptions in this specification, the terms used are for the purpose of describing specific embodiments only and are not intended to be limiting. When used in the description of the embodiments of the various descriptions and the appended claims, the singular forms ("a", "an", and "the") are intended to include the plural forms as well, unless the context clearly dictates otherwise. Also, the term "and / or" as used in this specification, when used, refers to any and all possible combinations of one or more of the associated listed items and is understood to be used to encompass this. Further, the terms "comprising" or "including" as used in this specification, when used, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0012] As used in this specification, the term "when" is optionally interpreted, depending on the context, to mean "when", or "as soon as", or "in response to a determination", or "in response to a detection". Similarly, the phrases "when determined" or "when [stated condition or event] is detected" are optionally interpreted, depending on the context, to mean "as soon as determined", or "in response to a determination", or "as soon as [stated condition or event] is detected", or "in response to a detection of [stated condition or event]".

[0013] FIG. 1 illustrates a seat assembly 20 as an in-vehicle seat assembly 20 according to an embodiment. Although the in-vehicle seat assembly 20 is illustrated and described, any seat assembly 20 can be used. The seat assembly 20 can be used in land vehicles, aircraft, ships, etc. The seat assembly 20 can also be used as an office chair, a comfort chair, etc.

[0014] The seat assembly 20 includes a seat bottom cushion 22 that supports the pelvis and thighs of a seated occupant. The seat assembly 20 further includes a seat back cushion 24 that supports the back and shoulders of a seated occupant. The seat assembly 20 further includes a headrest 26 that supports the neck and head of a seated occupant. A trim cover 28 is provided over the seat cushions 22, 24 and the headrest 26 to conceal the cushions 22, 24 and the headrest 26 and provide a uniform and smooth contact surface to the occupant.

[0015] Referring to FIG. 2, the product is shown. In the illustrated embodiment, the product is the seat cushion 22 shown in a disassembled state from the seat assembly 20. The cushion 22 includes a body 30. According to one embodiment, the cushion 22 can have a non-rectangular cross-section. The body 30 is composed of a strand mesh 32 of foamed thermoplastic resin. The strand mesh 32 includes three-dimensional filament loops extruded from a thermoplastic polymer. The thermoplastic polymer is composed of one component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

[0016] Referring now to FIG. 3, the seat cushions 22, 24 are manufactured from an extruded thermoplastic resin mesh system 34 and process. A hopper 36 holds the raw material to be extruded, such as solid particles or pellets of the material. The material can be supplied, for example, by a plastic such as linear low density polyethylene (LLDPE). The material is supplied from the hopper 36 to an extruder 38.

[0017] The extruder 38 melts the material and conveys it to the die plate 40. In one non-limiting example, the extruder 38 includes both a barrel that houses a rotatable screw or auger and a heating element. The rotation of the screw exerts a force on the material to move it through the barrel, and the friction generated as the screw rotates helps heat the material. The material exits the extruder 38 in a molten state under pressure.

[0018] The die plate 40 extrudes the material into a plurality of filaments 42. The die plate 40 can be provided as described below according to the extrusion direction with respect to the final members 22, 24 produced from the die plate 40. More specifically, the die plate 40 has a plurality of small circular through-holes or openings through which the molten material passes. A single filament 42 is extruded from each hole of the die plate. The filaments 42 fall downward from the die plate to the funnel 44 as described below under the pressure and gravity of the system. The funnel 44 can have a cross-sectional shape that is the same as or different from the shape collectively defined by the openings in the die plate 40.

[0019] The funnel 44 helps integrate or gather the filaments 42 into a more compact arrangement where the filaments 42 bend or loop and each filament 42 contacts and bonds to at least one other filament 42. The funnel 44 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. The funnel 44 is narrower at the funnel outlet than at the funnel inlet. The individually separated filaments 42 enter the funnel inlet, the filaments 42 accumulate, and as the filaments 42 slide down toward the funnel outlet, the filaments 42 bend / loop, move into contact, and the integrated filament structure 46 exits the funnel outlet and immediately enters the water tank.

[0020] The liquid tank 48 holds water 50, a coolant, or another fluid and receives the integrated filament structure 46 from the funnel 44. The liquid 50 within the bath 48 helps to temporarily support the integrated filament structure 46, prevent the filament structure from collapsing or condensing into a closed or low-porosity configuration, and helps to maintain the desired porosity and density. To that end, the liquid 50 provides some resistance to cause further bending and looping of the filaments 42 so as to further build the integrated filament structure 46. Second, the liquid 50 cools the filaments 42 from the outside to solidify the filaments 42 and prevent the filaments 42 from bonding at further locations.

[0021] The tank 48 includes various rollers and conveyors, such as a tractor conveyor 52, that assist the integrated filament structure 46 in moving through and out of the liquid 50. The speed of the rollers and conveyors can be controlled to move the integrated filament structure 46 away from the funnel 44 at a speed that depends on the speed at which the integrated filament structure 46 exits the funnel 44.

[0022] Other rollers, such as roller 54, help to keep the integrated filament structure 46 submerged in the liquid 50 and guide the integrated filament structure 46 through the liquid 50 towards the conveyor belt 56 and shaker table 58 disposed outside the tank 48. The shaker table 58 vibrates the integrated filament structure 46 while it is on the conveyor belt 56 to remove the liquid 50. Additionally or alternatively, compressed air can be blown towards the integrated filament structure 46 and / or the integrated filament structure 46 can be squeezed to remove the liquid 50. Thereafter, the integrated filament structure 46 can be cut to the desired size and shape.

[0023] Figure 4 shows a cushioning material pad 60 formed by the system 34 of FIG. 3. The cushioning material pad 60 is extruded from the system 34 and then cut from the filament structure 46. The cushioning material pad 60 includes a body 30 formed from a strand mesh 32. The body 30 includes a strand mesh 32 of a certain density around a periphery having a non-rectangular cross-section. The strand mesh 32 around the periphery of the density is composed of a plurality of rows of strands. The density of the strand mesh 32 is greater around the periphery than inside the periphery of the body 30 so as to provide a contact surface around the periphery. As shown in the illustrated embodiment, the periphery also includes at least one recess 80. The recess 80 can be utilized as a groove for receiving other components of the seat assembly 20, such as a seat frame, ducts, wiring, etc.

[0024] The cushioning material pad 60 has the cross-section illustrated in FIG. 4. The cross-section is non-rectangular so that the cushioning material pad 60 is extruded having the desired shape of the cushioning material pad 60 to avoid or minimize secondary shipping processes and material waste. The cushioning material pad 60 can be a seat cushion or a part of a seat cushion that can be assembled with other seat cushion parts. The cushioning material pad 60 can be used for any stuffing application such as seat cushions, backrests, headrests, armrests, legrests, etc.

[0025] FIGS. 5-8 show a tool 62 provided in the funnel 44 of the system 34 of FIG. 3. The tool 62 includes an opening 64 sized to fit the overall cross-section of the cushion 22. The tool 62 has a non-rectangular cross-section that matches the overall non-rectangular cross-section of the cushion 22. The tool 62 may be three-dimensionally printed according to one embodiment. The tool 62 can be composed of a polymer material according to one embodiment. Alternatively, the tool can be formed from aluminum, stainless steel, or any suitable metal or alloy.

[0026] Tool 62 is utilized in the process of fabricating cushion 22. The process initially consists of discharging a plurality of strands 66 on the outer side of the molten thermoplastic resin through opening 64 of tool 62 while engaging them with tip 68 of tool 62. Tip 68 is illustrated as an angled chamber of tool 62. On the other hand, a plurality of strands 70 on the inner side of the molten thermoplastic resin are discharged through opening 64 of tool 62 without engaging them with tip 68 of tool 62. Thereafter, a fluid such as water is discharged through fluid line 72 passing through tool 62 to cool the tool and the plurality of strands 66, 70 as a solidified mesh. The fluid is discharged through fluid line 72 to cool tool 62 and, as a result, strand 70. The fluid also engages tip 68 before being discharged into opening 64 of tool 62.

[0027] Tool 62 includes a plurality of protrusions 82 extending inside opening 64 so as to form recess 80. Tool 62 can further include a plurality of tips 84 angled with a steeper slope than tip 68 that cooperate in the formation of recess 80.

[0028] Fluid line 72 surrounds the periphery of tip 68 and branches towards opening 64 of tool 62. Fluid line 72 is formed as a continuous loop for uniform fluid distribution. Fluid line 72 is connected to a plurality of inlets 74 formed around tool 62 for supplying water to fluid line 72. Inlets 74 are also connected to a plurality of outlets 76 for distributing fluid through opening 64. An outlet 76 for distributing fluid to recess 80 in cushion 60 is formed through protrusion 82. As illustrated in FIG. 7, a further fluid line 86 for carrying fluid to outlet 76 is provided on tool 62.

[0029] Before discharging the plurality of strands 66 outside the molten thermoplastic resin, the tip 68 can be lubricated by a fluid. During the discharge of the plurality of strands 66 outside the molten thermoplastic resin, the tip 68 can also be lubricated. The tip 68 further includes a fabric 78 that is displaced along the tip 68, as shown in FIG. 8. The fabric 78 can also be lubricated before or during the discharge of the plurality of outer strands 66.

[0030] FIG. 9 illustrates a tool 88 provided in the funnel 44 of the system 34 of FIG. 3 according to another embodiment. The tool 88 includes an opening 90 sized to match the overall cross-section of the cushion 22. The tool 88 has a non-rectangular cross-section that matches the overall non-rectangular cross-section of the cushion 22. The tool 88 may be three-dimensionally printed according to one embodiment. The tool 88 can be made of a polymer material according to one embodiment.

[0031] The tool 88 is utilized in the process of making the cushion 22. The process consists first of discharging a plurality of strands 66 outside the molten thermoplastic resin through the opening 90 of the tool 88 while engaging the strands 66 with the tip 92 of the tool 88. The tip 92 is shown as an angled chamber of the tool 88. On the other hand, a plurality of strands 70 inside the molten thermoplastic resin are discharged through the opening 90 of the tool 88 without engaging the tip 92 of the tool 88. Thereafter, a fluid such as water is discharged through a fluid line 94 passing through the tool 88 to cool the tool and the plurality of strands 66, 70 as a solidified mesh. The fluid is discharged through the fluid line 94 to cool the tool 88 and, as a result, the strands 70. The fluid also engages the tip 92 before being discharged into the opening 90 of the tool 88.

[0032] The fluid line 94 surrounds the periphery of the tip 92 and branches towards the opening 90 of the tool 88. The fluid line 94 is formed as a continuous loop for uniform fluid distribution. The fluid line 94 is connected to a plurality of inlets 96 formed around the tool 88 for supplying water to the fluid line 94. The inlets 96 can also be connected to a plurality of outlets for distributing fluid through the opening 90. The tip 92 can be lubricated by the fluid before discharging the plurality of outer strands 66 of the molten thermoplastic resin. The tip 92 can also be lubricated while discharging the plurality of outer strands 66 of the molten thermoplastic resin.

[0033] In at least one first aspect, which can be combined with any one of the aspects described below or can be otherwise, the product comprises a body having a non-rectangular cross-section obtained from a strand mesh of foamed thermoplastic resin. The density of the strand mesh around the periphery of the non-rectangular cross-section is greater than that inside the periphery. The periphery comprises at least one recess formed therein.

[0034] According to a second aspect, there is provided a product according to any one of the aspects described above or below, wherein the strand mesh of the above density around the periphery of the non-rectangular cross-section is configured as a plurality of rows of strands.

[0035] According to a third aspect, the sheet assembly comprises a sheet frame and a cushioning material pad. The body according to any one of the aspects described above or below is sized to obtain the cushioning material pad.

[0036] In claim 4, the method for manufacturing a product, which can be combined with any one of the above-described or the following claims or can be otherwise, discharges a plurality of strands of molten thermoplastic resin through a tool having an opening sized to fit the overall cross-section of the product. The plurality of strands outside the molten thermoplastic resin engage the tip of the tool. The plurality of strands of molten thermoplastic resin pass through the opening. The plurality of strands inside the molten thermoplastic resin pass through the opening with a gap inside the tip. Fluid is discharged through a fluid line formed through the tool.

[0037] According to claim 5, the method according to any one of the above-described or the following claims is provided, and the tool has a non-rectangular cross-section that fits the overall non-rectangular cross-section of the product.

[0038] According to claim 6, the method according to any one of the above-described or the following claims includes discharging fluid from the fluid line to the opening of the tool.

[0039] According to claim 7, the method according to any one of the above-described or the following claims includes discharging fluid from the fluid line along the tip.

[0040] According to claim 8, the method according to any one of the above-described or the following claims includes lubricating the tip before discharging the molten thermoplastic resin.

[0041] According to claim 9, the method according to any one of the above-described or the following claims includes lubricating a fabric displaced along the tip before discharging the molten thermoplastic resin and discharging the molten thermoplastic resin.

[0042] According to claim 10, a product is provided and formed from the method according to any one of the above-described or the following claims.

[0043] According to claim 11, the product according to any one of the above-described or the following claims further includes a sheet cushioning material pad.

[0044] According to claim 12, the method according to any one of the foregoing or following claims includes installing the product as a cushioning material pad in the seat assembly.

[0045] According to claim 13, a seat assembly is manufactured by the method according to any one of the foregoing or following claims.

[0046] According to claim 14, the method according to any one of the foregoing or following claims includes a step of machining the body of the tool from a raw material.

[0047] According to claim 15, the method according to any one of the foregoing or following claims comprises three-dimensionally printing the tool.

[0048] In claim 16, the tool, which can be combined with or not combined with any one of the foregoing or following claims, comprises a tool body having a through-opening and a tip portion around the opening, the through-opening being sized to fit the overall periphery of the product, the tip portion and the through-opening being sized to receive the molten thermoplastic resin as a plurality of extruded strands, the tool through-opening being sized to maintain the plurality of extruded strands inside the overall periphery of the product, and a fluid line for cooling the tool and the plurality of strands being formed through the tool.

[0049] In claim 17, a tool according to any one of the foregoing or following claims is provided, and the tool through-opening is non-rectangular with a non-rectangular cross-section.

[0050] In claim 18, the tool according to any one of the foregoing or following claims comprises a plate.

[0051] In claim 19, the tool according to any one of the foregoing or following claims comprises a fluid joint around the periphery.

[0052] In claim 20, the tool of any one of the above-described or below-described claims includes a valve.

[0053] In claim 21, the tool of any one of the above-described or below-described claims includes a fabric installed on the tool.

[0054] In claim 22, the tool of any one of the above-described or below-described claims is provided, and the tool is formed from a polymer material.

[0055] In claim 23, the tool of any one of the above-described or below-described claims is provided, and the tool is three-dimensionally printed.

[0056] In claim 24, the tool of any one of the above-described or below-described claims is provided, and the fluid line surrounds the periphery of the tip.

[0057] In claim 25, the tool of any one of the above-described or below-described claims is provided, and the fluid line branches toward the opening of the tool.

[0058] In claim 26, the tool of any one of the above-described or below-described claims is provided, and the fluid line is formed in a continuous loop for uniform water distribution.

[0059] In claim 27, the tool of any one of the above-described or below-described claims includes a plurality of inlets for supplying water to the fluid line.

[0060] In claim 28, the tool of any one of the above-described claims includes a plurality of outlets for filtering fluid through the opening.

[0061] Although various 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 language used in this specification is for description rather than limitation, and that various modifications can be made without departing from the spirit and scope of the present disclosure. Additionally, features of various embodiments can be combined to form further embodiments according to the present disclosure.

Claims

1. 1. An article of manufacture comprising a body having a non-rectangular cross section comprising a strand mesh of expanded thermoplastic resin, a density of the strand mesh around a periphery of the non-rectangular cross-section is greater than within the periphery, the periphery having at least one recess formed therein.

2. The article of manufacture of claim 1 , wherein the strand mesh of the density around the periphery of the non-rectangular cross-section is configured as multiple rows of strands.

3. Seat frame and A seat assembly comprising: a cushioning pad, the body of claim 1 being sized to obtain said cushioning pad.

4. A method of manufacturing a product, comprising: Discharging a plurality of strands of molten thermoplastic resin through a tool having an opening sized to fit a general cross-section of the product; engaging a tip of the tool with the outer strands of the molten thermoplastic resin; passing the strands of the molten thermoplastic resin through the opening; passing a plurality of inner strands of the molten thermoplastic resin through the opening at intervals inwardly of the tip; and discharging fluid through a fluid line formed through the tool.

5. The method of claim 4 , wherein the tool has a non-rectangular cross-section that matches an overall non-rectangular cross-section of the product.

6. The method of claim 4 further comprising discharging fluid from the fluid line to the opening in the tool.

7. The method of claim 4 further comprising discharging fluid from the fluid line along the tip.

8. The method of claim 4 further comprising lubricating the tip prior to dispensing the molten thermoplastic resin.

9. 5. The method of claim 4, further comprising lubricating a fabric displaced along the tip prior to dispensing the molten thermoplastic resin, and dispensing the molten thermoplastic resin.

10. 5. The product formed from the method of claim 4.

11. 11. The article of manufacture of claim 10, further comprising a seat cushioning pad.

12. The method of claim 4 further comprising installing the product in a seat assembly as a cushioning pad.

13. A seat assembly produced by the method of claim 12.

14. The method of claim 4 further comprising machining the tool body from stock material.

15. The method of claim 4 further comprising three-dimensional printing the tool.

16. A tool having a tool body having a through opening and a tip portion around the opening, the through opening is sized to fit the overall periphery of the product; the tip and the through opening are sized to receive molten thermoplastic resin as a plurality of dispensed strands; the tool through opening is sized to maintain the plurality of extruded strands within the general perimeter of the product; A tool, wherein fluid lines are formed through the tool for cooling the tool and the plurality of strands.

17. The tool of claim 16 , wherein the tool through opening is non-rectangular having a non-rectangular cross-section.

18. The tool of claim 16 , wherein the tool body further comprises a plate.

19. The tool of claim 16 , wherein the tool further comprises a fluid coupling around the periphery.

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