Three-dimensional mesh structure

Abstract

To provide an apparatus containing a three-dimensional mesh structure.SOLUTION: A cushion comprises: a first body 110' comprising a plurality of extruded filaments 112 in which the extruded filaments 112 are randomly connected to each other to form a first three-dimensional structure; and a second body 110'' comprising the plurality of extruded polymer filaments in which the extruded filaments 112 are randomly connected to each other to form a second three-dimensional structure. In the first body 110', a contacted area is heated by an ultrasonic forming tool 132 to form a shape of the first body 110'. At least one welded portion 138 is formed between the first body 110' and the second body.SELECTED DRAWING: Figure 14

Description

Technical Field

[0001] This relates to a three-dimensional mesh structure and an assembly method.

Summary of the Invention

[0002] One object of the present invention is to provide a three-dimensional mesh structure and a method for assembling the same.

[0003] According to one aspect of the present invention, there is provided a body including a plurality of extruded polymer filaments randomly connected to form a three-dimensional structure of a first shape, heating a portion of the extruded polymer filaments with an ultrasonic tool, and welding at least some of the portions of the extruded polymer filaments with the ultrasonic tool to form the portion of the extruded polymer filaments into a second shape. A method is provided that includes doing so.

[0004] According to another aspect of the present invention, there is provided an apparatus including a body including a plurality of extruded polymer filaments randomly connected to form a first three-dimensional structure, the first three-dimensional structure including a first shape formed by the extruded polymer filaments, the body being formed by heating a region of the body using an ultrasonic tool for modifying a part of the extruded polymer filaments to form a second three-dimensional structure including a second shape different from the first shape. An apparatus is provided.

Brief Description of the Drawings

[0005]

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Embodiments for Carrying Out the Invention

[0006] Next, reference will be made in detail to the embodiments. 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 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.

[0007] It should be understood that the disclosed embodiments are merely illustrative and that various alternative forms are possible. The drawings are not necessarily drawn to an exact scale ratio, and some features may be exaggerated or minimized to show details of specific components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather should be interpreted as a representative basis for teaching those skilled in the art to variously employ the embodiments according to the present disclosure.

[0008] "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.

[0009] Also, although the terms first, second, etc. are used herein in some instances to describe various elements, 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 contact may be referred to as the second contact, and similarly, the second contact may be referred to as the first contact. The first contact and the second contact are both contacts, but they are not the same contact.

[0010] 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. When used in the description of the various described embodiments 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 herein, when referring to related listed items, is intended to cover any and all possible combinations of one or more of the associated listed items and is used to encompass the same. Further, the terms “comprising” or “including” as used herein are intended to specify the presence of the stated features, integers, steps, operations, elements, and / or components, but not to preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0011] As used herein, the term "when ~" is optionally construed, depending on the context, to mean "when ~", or "as soon as ~", or "depending on the determination", or "depending on the detection". Similarly, the phrases "when determined" or "when [specified condition or event] is detected" are optionally construed, depending on the context, to mean "as soon as the determination is made", or "depending on the determination", or "as soon as [specified condition or event] is detected", or "depending on the detection of [specified condition or event]".

[0012] Referring to FIGS. 1 and 3, an example of the three-dimensional mesh structure 110 of the seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for land vehicles such as cars, trucks, buses, or for non-land vehicles such as airplanes or ships. For example, the seat assembly 10 for a land vehicle can be shaped and sized as a front-row driver's seat or passenger seat, a second-row, third-row, or other rear-row seat, and can include a bucket seat, a bench seat, or other seat types as shown. Further, the seat assembly 10 may be a non-foldable seat, or a foldable and stowable seat that can be stowed in a cavity in the floor of the vehicle. In addition, the seat assembly 10 may be configured for non-vehicle uses such as furniture.

[0013] In the configuration shown in FIG. 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. In some configurations, it is contemplated that the seat back 22 may be omitted, such as when the seat assembly 10 is configured as a motorcycle seat, i.e., a saddle.

[0014] The seat bottom 20 is configured to receive the seated person and support the pelvis and thighs of the seated person. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0015] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and can be made of any suitable material such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In some configurations, the seat bottom frame 30 includes a panel on which the cushion 32 is disposed, a seat pan, a suspension mat, or suspension wires.

[0016] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a compliant material (elastic material) that supports the seated person and disperses the load gravity from the seated person to the seat bottom frame 30. The cushion 32 and related manufacturing methods will be described in more detail below.

[0017] The trim cover 34 covers at least a portion of the cushion 32. In addition, the trim cover 34 provides one or more visible outer surfaces of the seat back 22. A seated person can be disposed on the trim cover 34 when seated on the seat assembly 10. The trim cover 34 is made of any suitable single or plural materials, such as cloth, leather, synthetic leather, vinyl, or a combination thereof. The trim cover 34 can include a plurality of trim panels assembled by any suitable method such as fusing or stitching. The trim cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 can include trim attachment features that are attached to the seat bottom frame 30, the cushion 32, or both to prevent the trim cover 34 from coming off and to help conform the trim cover 34 to the contours of the seat bottom frame 30, the cushion 32, or both. The trim cover 34 may also be attached to an attachment pad, as will be described in more detail below.

[0018] The seat back 22 is configured to support the back of the seated person. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and in the vicinity of the rear side of the seat bottom 20. The seat back 22 extends substantially upward away from the seat bottom 20. In some configurations, the seat back 22 can be attached to the seat bottom 20 and be pivotable relative to the seat bottom 20. In other configurations, the seat back 22 is not attached to the seat bottom 20. For example, a vehicle seat back may be attached to the vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a trim cover 44, and an optional headrest 46.

[0019] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and can be made of any suitable material such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In some configurations, the seat back frame 40 includes a panel, a pan, a suspension mat, or a suspension wire on which the cushion 42 is disposed. It is also contemplated that the seat back frame 40 may be integrally formed with the seat bottom frame 30 in some configurations.

[0020] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a compliant material that supports the seated person and distributes the load gravity from the seated person to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be separate from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods will be described in more detail below.

[0021] The trim cover 44 covers at least a portion of the cushion 42. Additionally, the trim cover 44 provides one or more visible outer surfaces of the seat back 22. An occupant may be disposed on the trim cover 44 when seated on the seat assembly 10. The trim cover 44 is made from any suitable single or plural materials, such as cloth, leather, synthetic leather, vinyl, or combinations thereof. The trim cover 44 can include one trim panel, or a plurality of trim panels assembled in any suitable manner such as by fusing or stitching. The trim cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 can include trim attachment features attached to the seat back frame 40, the cushion 42, or both to prevent the trim cover 44 from coming off and to help conform the trim cover 44 to the contours of the seat back frame 40, the cushion 42, or both. The trim cover 44 may also be attached to a mounting pad, as will be described in more detail below.

[0022] When a headrest 46 is provided, the headrest 46 is configured to support the head of an occupant. The headrest 46 is disposed at the top of the seat back 22, i.e., at the end of the seat back 22 disposed on the opposite side of the seat bottom 20. The headrest 46 can be movable relative to the seat back 22 in one or more directions, or can be integrally formed with the seat back 22.

[0023] An example of a manufacturing system 60 for making a cushion, i.e., a filament mesh structure, is shown in FIG. 2. In this example, the manufacturing system 60 includes a material supply 70, an extruder 72, and a hopper 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0024] Referring to FIGS. 2 and 3, the material supply unit 70 holds the raw material to be extruded, such as solid beads, flakes, granules, pellets, or powder of the material. In some configurations, the material supply unit 70 is configured as a container or hopper. The material supply unit 70 supplies the raw material to the extruder 72.

[0025] The extruder 72 melts the raw material and extrudes the raw material into a plurality of filaments 112. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that houses a rotatable screw and a heating element. The rotation of the screw moves the material through the barrel and helps heat the material by the friction generated when the screw rotates. The material exits the barrel in a molten state under pressure and is transported under pressure to the die 80 of the extruder 72.

[0026] The die 80, which may also be referred to as a die plate or extrusion die, has a plurality of through holes, i.e., filament forming openings, through which the molten material passes. A single filament 112 is extruded from each through hole. The filaments 112 fall downward from the die 80 to the funnel 74 under gravity.

[0027] The funnel 74 integrates or groups the filaments 112 into a more compact arrangement where the filaments bend, curl, or loop and the filament 112 contacts and binds to at least one other filament 112. The funnel 74 has an inlet opening, i.e., the funnel inlet, and an outlet opening smaller than the funnel inlet, i.e., the funnel outlet. The individual, separated filaments 112 enter the funnel inlet. The filaments 112 bend, curl, or loop and move and contact as they accumulate. The filaments 112 move through the funnel 74 towards the funnel outlet. Some filaments may slide along the funnel 74 or an intervening sheet disposed on the funnel 74 as the filaments move towards the funnel outlet. Junctions are formed between the filaments 112 at the contact points, while openings or voids between the filaments 112 are present at other locations where one filament 112 does not contact or bind to another filament 112. The intertwined and bound filaments 112 pass through the funnel outlet of the funnel 74 and enter the cooling tank 76. For reference convenience, the combined filaments 112 are referred to as a mesh member or a filament mesh structure 110.

[0028] The cooling tank 76 holds a liquid such as water or a mixture of water and another fluid. The liquid in the cooling tank 76 serves to support the intertwined and bonded filaments 112 and limit further compression or consolidation of the filaments 112 into an arrangement with fewer openings or pores, maintaining the desired porosity and density of the filament mesh structure 110. Thus, the liquid provides a certain degree of buoyancy or resistance such that the filaments 112 can further bend, curl, or loop adjacent to the surface of the liquid or within the funnel 74 so as to further build the filament mesh structure 110. The liquid also cools the filaments 112 when the filaments 112 are in the liquid. For example, the liquid cools the filaments 112 from the outside to solidify the filaments 112 and prevent the filaments 112 from bonding at further locations. At this point, the filaments 112 become relatively rigid and are no longer in a plastic state, generally maintaining their shape and no longer being formable or re-formable without reheating.

[0029] The material handling subsystem 78 transports the filament mesh structure 110 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that assist in moving the filament mesh structure 110 out of the liquid through the liquid. In some configurations, a traction conveyor 92 is provided within the cooling tank 76 and serves to pull the filament mesh structure 110 away from the funnel 74 and counteract the buoyancy of the filaments 112.

[0030] One or more other rollers, such as roller 94, keep the filament mesh structure 110 immersed in the liquid and guide the filament mesh structure 110 through the cooling tank 76. For example, roller 94 can guide the filament mesh structure 110 toward the conveyor belt 96 and the vibrating machine table 98 disposed outside the cooling tank 76. The vibrating machine table 98 vibrates the filament mesh structure 110 while the filament mesh structure 110 is on the conveyor belt 96 to remove the liquid. Alternatively, or in addition, the filament mesh structure 110 may be squeezed to remove the liquid, air may be blown toward the filament mesh structure 110 to help remove the liquid from the filament mesh structure 110, or both. It is also contemplated that the filament mesh structure 110 can be dried by simply hanging it up or drying it in the ambient air.

[0031] The above manufacturing system 60 is a continuous flow process in which the filament mesh structure 110 is formed as a continuous structure when filament extrusion is not interrupted. Further processing of the filament mesh structure 110, which cuts the filament mesh structure 110 into individual parts or blanks for individual cushions, is provided after it exits the cooling tank 76. Such processing is performed by the cutting subsystem of the manufacturing system 60. The cutting system can be of any suitable type. For example, the cutting system can use a blade, knife, hot knife, saw, fluid jet, etc. to cut the filaments 112 of the filament mesh structure 110 into blanks. The cutting system can be used to shape or contour the blanks. It is also contemplated that the blanks may be further shaped or contoured by other manufacturing processes such as shaping the whole or a part of the blank.

[0032] Referring to FIGS. 1 and 3, an example of a three-dimensional mesh structure 110 is shown. The three-dimensional mesh structure 110 can be a cushion such as a cushion for a vehicle seat. The three-dimensional mesh structure 110 for a vehicle seat can be provided with a seat back 22, a seat bottom 20, or a combination thereof. The three-dimensional mesh structure 110 may be at least partially hidden by a trim cover 34 and may be directly or indirectly supported by a support structure of a seat assembly such as a seat bottom frame 30, a seat back frame 40, a panel, a support wire, etc. Alternatively, the three-dimensional mesh structure 110 can be used as a pad for other interior trim parts.

[0033] The three-dimensional mesh structure 110 is a three-dimensional mesh structure 110 formed by filaments 112 randomly looped and joined. In the drawings, the filaments 112 of the three-dimensional mesh structure 110 are represented by lines drawn randomly to represent a cross-sectional view of the three-dimensional mesh structure 110. The filaments 112 can be extruded filaments made of a thermoplastic material such as a thermoplastic resin of a polyamide-based, polyester-based, polyimide-based, polyolefin-based, polypropylene-based, polystyrene-based, or a combination thereof. The filaments 112 may be made of linear low-density polyethylene (LLDPE) or high-density polyethylene (HDPE). Therefore, the three-dimensional mesh structure 110 and its filaments 112 are not made of a foam such as urethane or polyurethane foam, and the three-dimensional mesh structure 110 can partially or completely replace a conventional foam seat cushion. When the filaments 112 contain reinforcing fibers, it is also contemplated that the reinforcing fibers need not be made of a thermoplastic polymer and may be an organic material, an inorganic material, or a thermosetting polymer.

[0034] The extruded filaments 112 may be randomly looped, curled, or intertwined, and may be joined at locations where one filament 112 contacts another filament, thereby providing a lightweight breathable cushion that defines openings or voids between the filaments 112. A method of making an extruded filament mesh cushion is disclosed in U.S. Patent Application No. 17 / 555,875, the entire disclosure of which is incorporated herein by reference.

[0035] Referring to FIGS. 1 and 3, an example of a three-dimensional mesh structure 110 including a cushion 32 is shown. The cushion 32 is generally designated by reference numeral 32 for convenience of reference. It should be understood that the structure and description of the cushion 32 are applicable to the cushion 32 at the seat bottom 20, the cushion 42 at the seat back 22, or both.

[0036] The cushion 32 is a non-foamed component or includes at least one non-foamed component. The non-foamed component is mainly referred to as a mesh member, but may also be referred to as a twisted member, a looped member, an intertwined member, a filament mesh structure, a mesh structure, a twisted mesh, a looped mesh, an intertwined mesh, or a mesh cushion. The cushion 32 is depicted as a non-foamed component that does not include a foamed component or foamed material such as urethane or polyurethane foam, but the cushion 32 may also include a foamed component or foamed material in addition to the non-foamed component, which is intended to provide additional cushioning or local cushioning to the seated person. For example, the foamed material can be provided between the cushion 32 and the trim cover (e.g., trim covers 34, 44), and the trim covers are disposed on, within, or in combination with the cushion 32. By reducing the amount of foamed material provided to the cushion 32 or eliminating the foamed material from the cushion 32, the weight can be reduced and the support and comfort of the seated person can be improved. In addition, by eliminating the foamed material, the recycling of the cushion 32 can be facilitated.

[0037] Regarding cushion 32, the situation where cushion 32 does not contain a foaming material will be described below. In this situation, the three-dimensional mesh structure 110 is made from filaments 112 of a polymer material that are randomly looped, bent, curled, or intertwined and joined, as will be described in more detail below. An example of filament 112 is shown in FIGS. 3 and 4. Filament 112 is directly joined to another filament 112, rather than being indirectly joined by a resin or other intermediate material.

[0038] Filament 112, which may also be referred to as a strand or thread, is made from any suitable single or plural materials. In some configurations, filament 112 is made from a polymer material or a thermoplastic material such as a thermoplastic resin that is polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based, or a combination thereof. As one example, a polyethylene-based filament may be made from linear low-density polyethylene (LLPDE). The filament material may be recyclable, unlike a foaming material, or may be recycled more easily than a foaming material. It is also contemplated that filament 112 may contain reinforcing fibers and that the reinforcing fibers may not be made from a thermoplastic material.

[0039] In some configurations, filament 112 may be a monofilament made from a single material. In some configurations, filament 112 is made from a plurality of materials. As an example, filament 112 made from a plurality of materials may include a core made from a first thermoplastic material and a sheath made from a second thermoplastic material that surrounds the core and is different from the first thermoplastic material. It is contemplated that cushion 32 may include a combination of a monofilament and filaments made from a plurality of materials and that are not monofilaments.

[0040] The filaments 112 that are randomly looped, bent, looped, curled, or intertwined are joined at locations where one filament 112 contacts another filament 112, thereby providing a lightweight breathable cushion (e.g., cushions 32 and / or 42) or a mesh structure that defines openings or voids between the filaments 112.

[0041] The process used to fabricate the three-dimensional mesh structure 110 can result in a three-dimensional mesh structure 110 having a substantially uniform cross-section, such as a rectangular cross-section. Further, the filaments 112 of the three-dimensional mesh structure 110 may be cooled and cured such that the filaments 112 become relatively rigid and are no longer formable or moldable in a plastic state. The substantially uniform cross-section may not provide a desired seat profile or other component profile. The cross-section of the three-dimensional mesh structure 110 is modified from its original substantially uniform cross-sectional profile to provide one or more depressions, protruding regions, curved regions, etc.

[0042] Referring to FIGS. 3 and 4, the three-dimensional mesh structure 110 is shown with a layer of film 114 attached to the outer surface of the three-dimensional mesh structure 110. In one embodiment, both the film 114 and the filaments 112 are formed from a thermoplastic material such as linear low-density polyethylene (LLDPE) or high-density polyethylene (HDPE). The film 114 is wrapped around the outer surface of the three-dimensional mesh structure 110, and heat is applied to the film 114 and the three-dimensional mesh structure 110 to melt the film 114 and weld the film 114 to the filaments 112.

[0043] Referring to FIG. 5, the ultrasonic tool 116 is operated as an end effector of the robot 119. The ultrasonic tool 116 is shown inserted between two three-dimensional mesh structures 110' and 110''. The ultrasonic tool 116 heats the two three-dimensional mesh structures 110' and 110'' by ultrasonic waves at the location where they are to be welded. Alternatively, the tool 116 can be equipped with a resistive heating system or a laser heating system can be used to heat the two three-dimensional mesh structures 110' and 110'' to weld them.

[0044] Referring to FIGS. 6 and 7, an internal grooving system is disclosed, and the ultrasonic grooving tool 118 is shown forming a groove 120 in the three-dimensional mesh structure 110. The ultrasonic grooving tool 118 forms a first wall 122A by welding a portion of the extruded polymer filament 112 on one side of the grooving tool 118, and forms a second wall 122B by welding a second portion of the extruded polymer filament 112 on the other side of the grooving tool 118, thereby forming a groove 120 including the two walls 122A and 122B. Referring to FIG. 7, the grooving tool 118 is shown completely penetrating the three-dimensional mesh structure 110 lined by a support member 124 defining a relief opening 126.

[0045] Referring to FIGS. 8A - 8D, examples of four different uses of the above-described grooving tool 118 are shown. In FIG. 8A, the groove hole (slot) 120 defined by the mesh structures 110' and 110'' extends completely through the two three-dimensional mesh structures 110' and 110''. In FIG. 8B, the groove hole 120 defined by the mesh structures 110' and 110'' extends completely through the first three-dimensional mesh structure 110' and partially through the second three-dimensional mesh structure 110''. In FIG. 8C, the groove hole 120 defined by the mesh structures 110' and 110'' extends partially through a single three-dimensional mesh structure 110. In FIG. 8D, the groove hole 120 defined by the mesh structures 110' and 110'' extends completely through the two three-dimensional mesh structures 110, as in FIG. 8A. The grooving tool 118 (shown in FIG. 7) also forms a relief region 128 while the grooving tool 118 plunge cuts the groove 120. The relief region 128 is formed by the upper portion of the grooving tool 118.

[0046] Referring to FIGS. 9 and 10, an ultrasonic forming tool 132 is shown, and the ultrasonic forming tool 132 has a symmetric shape that adjusts and equalizes the ultrasonic output of the forming tool 132. The tool 132 is moved to engage the three-dimensional mesh structure 110 shown in FIG. 10. The three-dimensional mesh structure 110 is initially provided as a rectangular block, as shown by the solid lines in FIG. 10. After being formed by the forming tool 132, the three-dimensional mesh structure 110 is formed to have a rounded outer periphery, as shown by the dashed lines in FIG. 10. By heating the filament 112 (shown in FIGS. 3 and 4) using ultrasonic energy, the filament 112 melts and approaches the melting point of the filament 112 while pressure is applied by the forming tool 132. When the forming tool 132 retracts, the filament 112 cools and retains the shape pressed by the forming tool 132. The forming tool 132 can also be used to form shallow-depth surface features.

[0047] Referring to FIG. 11, an alternative embodiment of the forming tool 134 is shown, which is provided as two semi - bodies that are anti - symmetric to adjust and balance the ultrasonic output of the forming tool 134. The tool 134 is used in a similar manner as the tool in FIG. 9.

[0048] Referring to FIGS. 12 - 14, a process for forming the plate - like part 138 or the receiving part 136 in the three - dimensional mesh structures 110’ and 110’’ is disclosed. The receiving part 136 includes a clip, a rod - shaped part, or a part of the plate - like part 138 to which various fasteners are fixed for attaching a seat cover, a trim part, or other accessories to the three - dimensional mesh structure 110. In FIG. 12, an ultrasonic tool 116 such as a welding horn or a sonicator is disposed above the two three - dimensional mesh structures 110’ and 110’’. In FIG. 13, the ultrasonic tool 116 is shown penetrating the top three - dimensional mesh structure 110’ (as shown). The term “top” mesh structure 110’ refers to the orientation shown in FIG. 12 and does not limit the present disclosure to any particular orientation. Then, the ultrasonic tool 116 is moved back and forth with respect to the lower three - dimensional mesh structure 110’’ as indicated by the arrow in FIG. 13, generating ultrasonic vibrations and friction between the two mesh structures 110’ and 110’’, and forming a plate - like part 138 as shown in FIG. 14 of the molten polymer between the two three - dimensional mesh structures 110’ and 110’’.

[0049] According to one aspect of the present disclosure, a method is disclosed that includes the steps of providing a body 110 including a plurality of extruded polymer filaments 112 that are randomly connected to form a three - dimensional structure of a first shape, heating a portion of the extruded polymer filaments 112 with an ultrasonic tool 116, and welding at least some of the portions of the extruded polymer filaments 112 with the ultrasonic tool 116 to form the portions of the extruded polymer filaments 112 into a second shape.

[0050] Another aspect of this method further includes assembling the film 114 to the body 110 of the second shape and heating at least a portion of the film 114 and the extruded polymer filaments 112 to weld the film 114 to the extruded polymer filaments 112 to form a surface layer (skin) on the body 110.

[0051] According to another aspect of the method, the plurality of extruded polymer filaments 112 define a plurality of spaces across which the film 114 is spanned in the body 110.

[0052] Another aspect of this method is a second body 110'' including a second plurality of extruded polymer filaments 112 that are randomly connected to form a second three-dimensional structure, the second three-dimensional structure including a second outer surface formed by the extruded polymer filaments 112, the method further including providing the second body 110''; contacting and assembling the first outer surface of the first body 110' with the second outer surface of the second body; heating a first region of the first outer surface of the first body 110' and a second region of the second outer surface of the second body 110''; and welding the first region of the first outer surface of the first body 110' to the second region of the second outer surface of the second body 110'' to join the first body 110' to the second body 110''.

[0053] According to one aspect of the present disclosure, to form the body 110, a portion of the body of the extruded polymer filaments 112 is cut using an ultrasonic cutting tool 116.

[0054] Another aspect of this method further includes inserting an ultrasonic tool 116 into at least a portion of the body 110 to form a groove 120 including a first wall 122A formed by welding a first portion of the extruded polymer filaments 112 and a second wall 122B formed by welding a second portion of the extruded polymer filaments.

[0055] Another aspect of this method includes contacting an ultrasonic tool 116, which is an ultrasonic welding tool, with a local area of the body 110, and welding the extruded polymer filaments 112 in the local area contacted by the ultrasonic welding tool 116 to join the extruded polymer filaments 112 in the local area, and forming a three-dimensional structure of a first shape into a second shape different from the first shape.

[0056] Another aspect of this method includes passing through the body 110 with an ultrasonic tool 116, which is an ultrasonic welding tool, in a local area on the outer surface of the body 110, and compressing the extruded polymer filaments 112 at a location inside the body 110 with the ultrasonic welding tool 116, and welding the extruded polymer filaments 112 compressed by the ultrasonic welding tool 116 to join the extruded polymer filaments 112 at a location inside the body 110.

[0057] According to another aspect of the present method, the extruded polymer filaments 112 are formed from linear low-density polyethylene or high-density polyethylene.

[0058] Another aspect of this method includes assembling a film 114 formed from linear low-density polyethylene or high-density polyethylene to the body 110, and heating at least a portion of the film 114 and the extruded polymer filaments 112, and welding the film 114 to the extruded polymer filaments 112 to form a surface layer on the body 110.

[0059] Another aspect of this method further includes inserting an ultrasonic tool 116 into at least a portion of the body 110 to form a groove 120 consisting of a first wall 122A formed by welding a first portion of the extruded polymer filaments and a second wall 122B formed by welding a second portion of the extruded polymer filaments, and the step of inserting the ultrasonic tool 116 into the body 110 is performed by partially or completely inserting the ultrasonic tool 116 into the body 110.

[0060] According to another aspect of the present method, the ultrasonic tool 116 is operated by a robot 119.

[0061] According to one aspect of the present disclosure, a body 110 including a plurality of extruded polymer filaments 112 randomly connected to form a first three-dimensional structure, the first three-dimensional structure including a first shape formed by the extruded polymer filaments 112, and heating a region of the body 110 using an ultrasonic tool 116 that modifies a portion of the extruded polymer filaments 112 to form the body 110 to form a second three-dimensional structure including a second shape different from the first shape. An apparatus is disclosed that includes:

[0062] According to another aspect of the present apparatus, the surface layer of the extruded polymer film 114 is welded to the extruded polymer filaments 112 on the second three-dimensional structure including the second shape.

[0063] According to another aspect of the present apparatus, the body 110 is a first body 110' including the second shape, and the present apparatus is a second body including a plurality of extruded polymer filaments 112 randomly connected to form a second three-dimensional structure, the second three-dimensional structure being formed by the extruded polymer filaments 112, and at least one weld formed between the first body and the second body. The second body 110'' is further provided.

[0064] According to another aspect of the present apparatus, the body defines at least one internal groove 120 including at least a first wall 122A and a second wall 122B facing each other, and the first wall 122A and the second wall 122B are formed by welding a first portion of the extruded polymer filaments at the first wall 122A and welding a second portion of the extruded polymer filaments at the second wall 122B.

[0065] According to another aspect of the present device, the main body 110 defines an opening 120 extending from the first outer periphery of the main body 110 to a location within the main body 110, and at the location within the main body 110, at least some of the extruded polymer filaments 112 are welded to form the attachment fixing portion 136.

[0066] According to another aspect of the present device, the attachment fixing portion 136 formed at a location inside the main body 110 is selected from the group including a fastener receiving portion, a clip, a planar member 138, or a loop.

[0067] According to another aspect of the present device, the surface layer of the extruded polymer film 114 welded to the extruded polymer filaments 112 of the three-dimensional structure including the second shape is formed of linear low-density polyethylene or high-density polyethylene.

[0068] Exemplary embodiments have been described above, but these embodiments are not intended to represent all possible forms according to the present disclosure. In that regard, the language used herein is for description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the present disclosure. Additionally, the features of various embodiments can be combined to form further embodiments according to the present disclosure.

[0069] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 452,914, filed on March 17, 2023, the disclosure of which is hereby incorporated by reference in its entirety as part of this specification.

Claims

1. Providing a body including a plurality of extruded polymer filaments that are randomly connected to form a three-dimensional structure of a first shape; Heating a portion of the extruded polymer filaments with an ultrasonic tool; Welding at least some of the portion of the extruded polymer filaments with the ultrasonic tool to form the portion of the extruded polymer filaments into a second shape; A method comprising.

2. Assembling a film to the body of the second shape; Heating at least a part of the film and the extruded polymer filaments, and welding the film to the extruded polymer filaments to form a surface layer on the body; The method according to claim 1, further comprising.

3. The method according to claim 2, wherein the plurality of extruded polymer filaments define a plurality of spaces in the body over which the film is spanned.

4. The body is a first body including a first outer surface, The method is, Providing a second body including a second plurality of extruded polymer filaments that are randomly connected to form a second three-dimensional structure, the second three-dimensional structure including a second outer surface formed by the second plurality of extruded polymer filaments; Contacting and assembling the first outer surface of the first body with the second outer surface of the second body; Heating a first region of the first outer surface of the first body and a second region of the second outer surface of the second body; Welding the first region of the first outer surface of the first body to the second region of the second outer surface of the second body to join the first body to the second body; The method according to claim 1, further comprising.

5. The method according to claim 1, further comprising cutting a portion of the body of the extruded polymer filaments using an ultrasonic cutting tool to form the body.

6. The method according to claim 1, further comprising inserting the ultrasonic tool into at least a portion of the body to form a groove composed of a first wall formed by welding a first portion of the extruded polymer filaments and a second wall formed by welding a second portion of the extruded polymer filaments.

7. Contacting the ultrasonic tool, which is an ultrasonic welding tool, with a local region of the body; Welding the extruded polymer filaments in the local area contacted by the ultrasonic welding tool to bond the extruded polymer filaments in the local area, and forming the three-dimensional structure of the first shape into a second shape different from the first shape; The method according to claim 1, further comprising.

8. Penetrating the main body in a local area of the outer surface of the main body with the ultrasonic tool, which is the ultrasonic welding tool, and compressing the extruded polymer filament at a location inside the main body with the ultrasonic welding tool; Welding the extruded polymer filament compressed by the ultrasonic welding tool to bond the extruded polymer filament at the location inside the main body, and forming a mounting and fixing portion at the location inside the main body; The method according to claim 1, further comprising.

9. The method according to claim 1, wherein the extruded polymer filament is formed from linear low-density polyethylene or high-density polyethylene.

10. Assembling a film formed from linear low-density polyethylene or high-density polyethylene to the main body; Heating at least a part of the film and the extruded polymer filament, and welding the film to the extruded polymer filament to form a surface layer on the main body; The method according to claim 1, further comprising.

11. Further comprising inserting the ultrasonic tool into at least a part of the main body to form a groove composed of a first wall formed by welding a first part of the extruded polymer filament and a second wall formed by welding a second part of the extruded polymer filament; Inserting the ultrasonic tool into the main body is performed by partially or completely inserting the ultrasonic tool into the main body, the method according to claim 1.

12. The method according to claim 11, wherein the ultrasonic tool is operated by a robot.

13. A main body including a plurality of extruded polymer filaments randomly connected to form a first three-dimensional structure, wherein the first three-dimensional structure includes a first shape formed by the extruded polymer filaments, the main body; Forming the body by heating a region of the body with an ultrasonic tool that modifies a portion of the extruded polymer filament to form a second three-dimensional structure including a second shape different from the first shape. An apparatus comprising.

14. The apparatus according to claim 13, further comprising a surface layer of an extruded polymer film welded to the extruded polymer filament of the second three-dimensional structure including the second shape.

15. The body is a first body including a second shape, A second body including a plurality of extruded polymer filaments randomly connected to form a second three-dimensional structure, wherein the second three-dimensional structure is formed by the extruded polymer filaments, the second body; At least one weld formed between the first body and the second body; The apparatus according to claim 13, further comprising.

16. The body defines at least one internal groove including at least a first wall and a second wall facing each other, and the first wall and the second wall are formed by welding a first portion of the extruded polymer filament on the first wall and welding a second portion of the extruded polymer filament on the second wall. The apparatus according to claim 13.

17. The body defines an opening extending from a first outer periphery of the body to a location within the body, and at least some of the extruded polymer filaments are welded at the location within the body to form a mounting fixing portion. The apparatus according to claim 13.

18. The mounting fixing portion formed at the location inside the body is A fastener receiving portion; A clip; A planar member; A loop; The apparatus according to claim 17, selected from the group including.

19. Further comprising a surface layer of an extruded polymer film welded to the extruded polymer filament of the three-dimensional structure including the second shape, The surface layer of the extruded polymer film is formed from linear low density polyethylene or high density polyethylene. The apparatus according to claim 13.

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