Seat assembly and method of manufacture

Abstract

To provide a seat assembly and a method therefor.SOLUTION: A product such as a seat assembly includes a mesh member and a structural framework. The mesh member comprises a set of filaments of polymeric material, where at least two members of the set of filaments are looped and bonded to each other. The structural framework is embedded within the mesh member. The stiffness of the structural framework is greater than the stiffness of the mesh member.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present application relates to a seat assembly having a cushion with a filament mesh structure and a method of manufacturing the same.

[0002] This application claims the benefit of U.S. Patent Application No. 18 / 678,572, filed May 30, 2024, and Danish Patent Application No. PA202470212, filed August 9, 2024, the disclosures of which are incorporated by reference in their entireties. Summary of the Invention

[0003] SUMMARY OF THE INVENTION It is an object of the present invention to provide a seat assembly and method thereof. According to one aspect of the present invention, there is provided an article of manufacture comprising: a mesh member including a set of filaments of a polymeric material, wherein at least two members of the set of filaments are looped and bonded to one another; and a structural framework embedded within the mesh member, wherein the structural framework has a stiffness greater than the stiffness of the mesh member.

[0004] According to another aspect of the present invention, there is provided a method including forming a mesh member, the mesh member comprising a set of filaments of a polymeric material, at least two members of the set of filaments being looped and bonded to one another; and embedding one or more structural rods in the mesh member, wherein a stiffness of the one or more structural rods is greater than a stiffness of the mesh member.

[0005] According to a further aspect of the present invention, there is provided a method including forming a mesh member, the mesh member including a set of filaments of a polymeric material, at least two members of the set of filaments being looped and bonded to one another; and attaching a trim cover to the mesh member by securing the trim cover to one or more anchors embedded within the mesh member. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a perspective view of an example of a sheet assembly including a filament mesh structure. [Figure 2] FIG. 1 is a schematic diagram of an example manufacturing system for making a filament mesh structure. [Figure 3A] 1 is an exploded view of an example trim cover and cushion, the cushion comprising a filament mesh structure. [Figure 3B] FIG. 3B is an enlarged view of region 3B of FIG. 3A. [Figure 4] FIG. 1 is an exploded perspective view of a filament mesh structure including a structural framework. [Figure 5] FIG. 1 is a bottom view of a filament mesh structure including a structural framework. [Figure 6] FIG. 10 is a cross-sectional view of a filament mesh structure showing the attachment between the trim cover and the structural framework. [Figure 7] 10 shows a portion of a filament mesh structure illustrating an alternative attachment between the trim cover and the structural framework. [Figure 8] 1 is a flowchart of a method of manufacturing a portion of a seat assembly including a filament mesh structure, a structural framework, and a trim cover. DETAILED DESCRIPTION OF THE INVENTION

[0007] 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 the various embodiments being described. However, it will be apparent to those skilled in the art that the various embodiments described 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.

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

[0009] "One or more" includes functions performed by a single element, functions performed by one or more elements, e.g., in a distributed manner, multiple functions performed by a single element, multiple functions performed by multiple elements, or any combination of the above.

[0010] While terms such as "first," "second," and the like are used in some instances to describe various elements herein, it should be understood that these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact can be referred to as a second contact, and similarly, a second contact can be referred to as a first contact, without departing from the scope of the various embodiments described. A first contact and a second contact are both contacts, but are not the same contact.

[0011] The terminology used in the description of the various embodiments set forth herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in describing 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. It will also be understood that the term "and / or," as used herein, refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "include," "including," "comprise," and / or "comprising," when used herein, specify the presence of 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 herein, the term "if" is optionally interpreted to mean "upon" or "when" or "response to determining" or "response to detecting," depending on the context. Similarly, the phrases "if it is determined" or "if (specified condition or event) is detected" are optionally interpreted to mean "upon the determination of" or "response to determining" or "upon detecting (specified condition or event)" or "in response to detecting (specified condition or event)," depending on the context.

[0013] Referring to FIG. 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly, such as for a land vehicle, such as an automobile, truck, or bus, or for a non-land vehicle, such as an aircraft or watercraft. For example, a land vehicle seat assembly 10 may be configured and sized as a front driver or passenger seat, a second, third, or other rear seat, and may include the illustrated bucket-style seat, a bench-style seat, or other seat styles. Furthermore, the seat assembly 10 may be a retractable seat or a non-retractable seat that may be foldable and retractable within a cavity in the vehicle floor. Additionally, the seat assembly 10 may be configured for non-vehicle applications, such as furniture.

[0014] 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or a stool.

[0015] The seat bottom 20 is configured to receive an occupant and support the pelvis and thighs of the occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover .

[0016] 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 may 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, seat pan, suspension mat, or suspension wire on which the cushion 32 is placed.

[0017] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is formed of a conformable material that supports an occupant and distributes load forces from the occupant to the seat bottom frame 30. The cushion 32 and related manufacturing methods are described in more detail below.

[0018] The trim cover 34 covers at least a portion of the cushion 32. Additionally, the trim cover 34 provides one or more visible exterior surfaces of the seat back 22. An occupant sits on the trim cover 34 when seated in the seat assembly 10. The trim cover 34 may be made of any suitable material, such as fabric, leather, synthetic leather, vinyl, or a combination thereof. The trim cover 34 may include multiple trim panels assembled in any suitable manner, such as by 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 may include a trim attachment mechanism attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 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 a mounting pad, as discussed in more detail below.

[0019] The seat back 22 is configured to support the back of an occupant. 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 near the rear side of the seat bottom 20. The seat back 22 extends generally upwardly away from the seat bottom 20. In some configurations, the seat back 22 may be attached to the seat bottom 20 and pivotable relative to the seat bottom 20. In other configurations, the seat back 22 is not attached to the seat bottom 20. For example, the 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 optionally a headrest 46.

[0020] 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 may 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, pan, suspension mat, or suspension wires on which the cushion 42 is positioned. It is also contemplated that in some configurations, the seat back frame 40 may be integrally formed with the seat bottom frame 30.

[0021] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is formed of a conformable material that supports an occupant and distributes load from the occupant to the seat back frame 40. The cushion 42 may be formed integrally 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 are described in more detail below.

[0022] The trim cover 44 covers at least a portion of the cushion 42. Additionally, the trim cover 44 provides one or more visible exterior surfaces of the seat back 22. An occupant sits on the trim cover 44 when seated in the seat assembly 10. The trim cover 44 may be made of any suitable material, such as fabric, leather, synthetic leather, vinyl, or a combination thereof. The trim cover 44 may include a single trim panel or multiple 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 may include a trim attachment mechanism attached to the seat back frame 40, the cushion 42, or both to prevent removal of the trim cover 44 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 discussed in more detail below.

[0023] If provided, the headrest 46 is configured to support the head of an occupant. The headrest 46 is located at the top of the seat back 22 or at the end of the seat back 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be formed integrally with the seat back 22.

[0024] 2, material supply 70 holds the material stock to be extruded, such as solid beads, flakes, granules, pellets, or powder made of the material. In some configurations, material supply 70 is configured as a container or hopper. Material supply 70 supplies the material stock to extruder 72.

[0025] The extruder 72 melts the material stock and extrudes it into sets of filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw moves the material through the barrel and helps heat the material due to friction generated as the screw rotates. The material exits the barrel in a molten state under pressure and is transported under pressure to a die 80 of the extruder 72.

[0026] The die 80, also known as a die plate or extrusion die, has a plurality of through-holes or filament-forming openings through which molten material passes. One filament 52 is extruded from each through-hole. The filaments 52 fall downward from the die 80 under gravity into the funnel 74.

[0027] The funnel 74 consolidates or groups the filaments 52 into a more compact configuration by bending, curling, or looping the filaments 52 so that they contact and bond with at least one other filament 52. The funnel 74 has an entrance opening or funnel inlet and an exit opening or funnel outlet that is smaller than the funnel inlet. Individual, separated filaments 52 enter the funnel inlet. As they accumulate, the filaments 52 bend, curl, or loop and contact each other. The filaments 52 move through the funnel 74 toward the funnel outlet. Some filaments slide along the funnel 74 or an interposer sheet disposed on the funnel 74 as they move toward the funnel outlet. While bonds are formed between the filaments 52 at the contact points, openings or voids exist between the filaments 52 at other locations where the filaments 52 do not contact or bond with another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter a cooling tank 76. For ease of reference, the joined filaments 52 are referred to as a mesh member or filament mesh structure 90 .

[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 helps support the entangled and bonded filaments 52 and further compress or consolidate the filaments 52, limiting them from becoming less open or porous, thereby maintaining the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance, which can further bend, curl, or loop the filaments 52 adjacent the surface of the liquid or within the funnel 74 to build additional filament mesh structure 90. The liquid also cools the filaments 52 while they are in the liquid. For example, the liquid can cool the filaments 52 from the outside, solidifying them and preventing them from bonding at additional locations. At this point, the filaments 52 are relatively rigid and no longer in a plastic state; therefore, they generally retain their shape and are not moldable or reshapeable without being reheated.

[0029] The material handling subsystem 78 transports the filament mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that help move the filament mesh structure 90 through and out of the liquid. In some configurations, a tractor conveyor 92 is provided within the cooling tank 76 to pull the filament mesh structure 90 out of the funnel 74 and help counteract the buoyancy of the filaments 52.

[0030] One or more other rollers, such as roller 94, keep the filament mesh structure 90 submerged in the liquid and guide the filament mesh structure 90 through the cooling tank 76. For example, roller 94 can guide the filament mesh structure 90 toward a conveyor belt 96 and a vibrating table 98 located outside the cooling tank 76. The vibrating table 98 vibrates the filament mesh structure 90 while it is on the conveyor belt 96 to remove the liquid. Alternatively or additionally, the filament mesh structure 90 can be compressed to remove the liquid, air can be blown toward the filament mesh structure 90 to help remove the liquid from the filament mesh structure 90, or both. It is also contemplated that the filament mesh structure 90 can be allowed to drain dry or to dry in ambient air.

[0031] The above-described manufacturing system 60 is a continuous flow process in which the filament mesh structure 90 is formed as a continuous structure when the extrusion of the filaments is uninterrupted. Further processing of the filament mesh structure 90 is provided after it exits the cooling tank 76, cutting the filament mesh structure 90 into individual pieces or blanks for individual cushions. Such processing is performed by a cutting subsystem of the manufacturing system 60. The cutting system may be of any suitable type. For example, the cutting system may use a blade, knife, hot knife, saw, fluid jet, or the like to cut the filaments 52 of the filament mesh structure 90 into blanks. The cutting system may be used to form or contour the blank. It is also contemplated that the blank may be further formed or contoured in other manufacturing processes, such as molding the entire blank or a portion thereof.

[0032] 3A and 3B, an example of a cushion 50 is shown. For ease of reference, the cushion is generally designated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 may be applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0033] The cushion 50 is a non-foamed component or includes at least one non-foamed component. The non-foamed component is primarily referred to as a mesh component, but may also be referred to as a stranded component, a looped component, an intertwined component, a filament mesh structure, a mesh structure, a stranded mesh, a looped mesh, an intertwined mesh, or a mesh cushion. The cushion 50 is described below in the context of a cushion 50 that does not include a foamed material. In this regard, the cushion 50 is made of filaments 52 of a polymeric material that are randomly looped, bent, curled, or intertwined and bonded to one another. The filaments 52 are bonded directly to one another, rather than indirectly to a resin or other intermediate material.

[0034] The filaments 52, which may also be referred to as strands or threads, are made of any suitable material. In some configurations, the filaments 52 are made of a polymeric or 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 an example, a polyethylene-based filament may be made from linear low-density polyethylene (LLPDE). The filament material may be recyclable, unlike, or more easily recycled than, a foamed material. It is also contemplated that the filaments 52 may include reinforcing fibers, and the reinforcing fibers need not be made from a thermoplastic material.

[0035] In some configurations, the filament 52 may be a monofilament made of a single material. In some configurations, the filament 52 is made of multiple materials. By way of example, a multi-material filament 52 may include a core made of a first thermoplastic material and a sheath surrounding the core made of a second thermoplastic material different from the first thermoplastic material. It is contemplated that the cushion 50 may include a combination of monofilaments and non-monofilament multi-material filaments.

[0036] The randomly looped, bent, curled, or tangled filaments 52 are bonded together where one filament 52 contacts another filament 52, thereby resulting in a lightweight, breathable cushion (e.g., cushion 32 and / or 42) or mesh structure having openings or voids between the filaments 52. An example of a manufacturing system 60 for making a cushion or 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 funnel 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0037] Referring to FIG. 3A , an exploded view of a portion of a seat assembly 10 is shown, including an example cushion 50 and an example trim cover 100. The trim cover 100 may be made from a fabric, textile, or textile material. The trim cover 100 may also be referred to as a seat or fabric cover. The cushion 50 includes a filament mesh structure 90. In FIG. 3A , the cushion 50 is shown without the individual filaments 52 of the filament mesh structure 90 for clarity. In some configurations, the cushion 50 has a contoured outer surface 110. The contoured outer surface 110 may have a partially or completely non-planar profile and may include one or more curved surfaces or regions. In some configurations, the contoured outer surface 110 may be concave or partially concave. The contoured outer surface 110 faces toward the trim cover 100. Additionally, the contoured outer surface 110 may face toward the occupant. The contoured outer surface 110 may contact a portion of the trim cover 100 in one or more regions.

[0038] The trim cover 100 is generally referred to by the reference numeral 100 for ease of reference. It should be noted that the trim cover 100 may be the trim cover 34 of the seat bottom 20 or the trim cover 44 of the seat back 22, as described above. A portion of the trim cover 100 is shown in FIG. 3A to better visualize other features in this view. The trim cover 100 may generally follow the curvature or contour of the cushion 50 when placed over and secured to the cushion 50 comprising the filament mesh structure 90. The trim cover 100 and the cushion may collectively form a manufactured product, such as the vehicle seat bottom 20 or the vehicle seat back 22.

[0039] 4-7, a product 112 (e.g., a seat assembly 10, a seat bottom 20, a seat back 22, or other subcomponent of the seat assembly 10) is shown. The product 112 includes a mesh member or filament mesh structure 90 that includes a cushion 50. The product 112 may also include a trim cover 100 or a portion of a trim cover 100. The product 112 further includes a structural support or framework 114 embedded in the filament mesh structure 90. The structural framework 114 includes one or more cords, coated wire cords, bent wires, rods, bars, etc. For example, the structural support may include one or more U-shaped bent cords, wires, rods, or bars 116 (e.g., FIG. 4), one or more straight cords, wires, rods, or bars 118 (e.g., FIG. 5), one or more curved, arc-shaped, or bent cords, wires, rods, or bars 120 (e.g., FIG. 5), one or more corrugated cords, wires, rods, or bars 122 (e.g., FIG. 5), etc. The structural framework 114 is made from a material that has a stiffness greater than that of the filament mesh structure 90. This increases the overall structural integrity of the product 112. For example, the structural support may be made from a sufficiently rigid material such as plastic polyethylene (e.g., linear low density polyethylene, low density polyethylene, high density polyethylene, etc.), other elastic polymers (e.g., thermoplastic polyester elastomers, thermoplastic polyurethanes, thermoplastic vulcanizates, etc.), the same material as the filament mesh structure 90, or a metallic material (e.g., steel, brass, copper, aluminum, aluminum alloys, etc.).

[0040] The structural framework 114 further operates to provide one or more attachment points for the trim cover 100. More specifically, the trim cover 100 may be disposed over the exterior of the filament mesh structure 90 and secured to the structural framework 114. Accordingly, the structural framework 114, or the cords, wires, rods, or bars that comprise the structural framework 114, may also be referred to as one or more anchors.

[0041] One or more connectors 124 may extend from the trim cover 100, through slots, slits, or openings 127 cut into and defined by the filament mesh structure 90, into the filament mesh structure 90, and engage the structural framework 114 to secure another trim cover 100 to the structural framework 114. The one or more connectors 124 may comprise Duon® tie-downs, typar / beaded Duon® connectors 125 (e.g., FIG. 6), bungee cords, other elastic cords, non-elastic cords, clips, hog rings 126 (e.g., FIG. 7), or the like.

[0042] The structural framework 114, or the cords, wires, rods, or bars comprising the structural framework 114, may be attached to the filament mesh structure 90 by overmolding the filaments 52 onto the structural framework 114. Alternatively, the structural framework 114, or the cords, wires, rods, or bars comprising the structural framework 114, may be placed within slots, slits, or openings 128 cut into and defined by the filament mesh structure 90. A molding or overmolding process may occur after the structural framework 114, or the cords, wires, rods, or bars comprising the structural framework 114, are placed within the slots, slits, or openings 128. Such a molding or overmolding process may include forming the filament mesh structure 90 into a final shape (e.g., the final shape of the cushion 50), or may include depositing additional filaments 52 or other material into the slots, slits, or openings 128 and over the structural framework 114 after the structural framework 114 is placed within the slots, slits, or openings 128. The slots, slits, or openings 128 defined by the filament mesh structure 90 may be located on the opposite side of the filament mesh structure 90 relative to the trim cover 100 .

[0043] 8, a flowchart of a method 200 for manufacturing a portion of a seat assembly 10 including a filament mesh structure 90, a structural framework 114, and a trim cover 100 is shown. The method 200 begins at block 202, where the filament mesh structure 90 is formed. The filament mesh structure 90 may be formed according to the process illustrated in FIG. 2 and described herein.

[0044] Next, method 200 proceeds to block 204, where structural framework 114, or one or more structural cords, structural wires, structural rods, or structural bars comprising structural framework 114, are embedded within filament mesh structure 90. Structural framework 114 may be embedded within filament mesh structure 90 by overmolding filaments 52 onto structural framework 114, or by placing or inserting structural framework 114 within slots, slits, or openings 128 cut into and defined within filament mesh structure 90.

[0045] If the structural framework 114 is embedded within the filament mesh structure 90 by placing or inserting the structural framework 114 into slots, slits, or openings 128 defined by the filament mesh structure 90, the method 200 may include an additional step including forming (e.g., cutting) the slots, slits, or openings 128 along the bottom of the filament mesh structure 90 (e.g., on the opposite side of the filament mesh structure 90 from the trim cover 100). Such an additional step may occur after the step in block 202 and before the step in block 204. The slots, slits, or openings 127 may also be formed during such an additional step or in a separate step.

[0046] Method 200 may include further additional steps after block 204 in which, once the structural framework 114 is positioned within the slots, slits, or openings 128, a molding or overmolding process is utilized to deposit additional filaments 52 or other material into the slots, slits, or openings 128 and over the structural framework 114. Such a molding or overmolding process may be a separate step or may be part of a step occurring in the next block (i.e., block 206). In block 206, the filament mesh structure 90 is formed into a desired shape (e.g., the final shape of the cushion 50). The step in block 206 may occur after the step in block 204 and before the step in block 208.

[0047] The method 200 next proceeds to block 208, where the trim cover 100 is attached to the filament mesh structure 90. More specifically, the trim cover 100 may be attached to the exterior, or outer surface, of the filament mesh structure 90. Attaching the trim cover to the filament mesh structure 90 may include affixing the trim cover 100 to the structural framework 114, or one or more structural cords, wires, rods, or bars that comprise the structural framework 114. Securing the trim cover 100 to the structural framework 114, or one or more structural cords, wires, rods, or bars that comprise the structural framework 114, may include attaching the trim cover 100 to the structural framework 114 via one or more connectors 124. One or more connectors 124 may extend from the trim cover 100 through slots, slits, or openings 127 defined by or cut into the filament mesh structure 90 and engage the structural framework 114 or one or more structural cords, structural wires, structural rods, or structural bars that comprise the structural framework 114.

[0048] It should be understood that the flowchart of Figure 8 is for illustrative purposes only, and that method 200 should not be construed as being limited to the flowchart of Figure 8. Some of the steps of method 200 may be rearranged, while others may be omitted entirely.

[0049] Clause 1. An article of manufacture comprising: a mesh member including a set of filaments of a polymeric material, at least two members of the set of filaments being looped and bonded to one another; and a structural framework embedded within the mesh member, wherein the stiffness of the structural framework is greater than the stiffness of the mesh member.

[0050] Clause 2. The product of clause 1, further comprising a trim cover positioned over an exterior of the mesh member and secured to the structural framework.

[0051] Clause 3. The product of clause 2, further comprising a connector, the connector extending from the trim cover through the opening defined by the mesh member and engaging the structural framework to secure the trim cover to the structural framework.

[0052] Clause 4. The product of clauses 2-3, wherein the trim cover is attached to the structural framework via clips or hog rings.

[0053] Clause 5. The product of clauses 1-3, wherein the structural framework is attached to the filaments by overmolding the filaments onto the structural framework.

[0054] Clause 6. The product of clauses 1-5, wherein a structural framework is disposed within the openings defined by the mesh members.

[0055] Clause 7. The product of clauses 1-6, wherein the opening defined by the mesh member is located on an opposite side of the mesh member relative to a trim cover.

[0056] Clause 8. A product as described in clauses 1 to 7, where the product is a vehicle seat bottom.

[0057] Clause 9. A product as described in clauses 1 to 7, wherein the product is a vehicle seat back.

[0058] Clause 10. A method including: forming a mesh member, the mesh member comprising a set of filaments of a polymeric material, at least two members of the set of filaments being looped and interconnected; and embedding one or more structural rods within the mesh member, wherein a stiffness of the one or more structural rods is greater than a stiffness of the mesh member.

[0059] Clause 11. The method of clause 10, further comprising attaching a trim cover to an exterior of the mesh member.

[0060] Clause 12. The method of clauses 10-11, wherein attaching the trim cover to the exterior of the mesh member includes fastening the trim cover to one or more structures.

[0061] Clause 13. The method of clause 12, wherein securing the trim cover to the one or more structural rods includes attaching the trim cover to the one or more structural rods via connectors extending from the trim cover through openings defined by the mesh member and engaging the one or more structural rods.

[0062] Clause 14. The method of clauses 10-13, further comprising forming openings along a bottom of the mesh member, wherein embedding the one or more structural rods in the mesh member comprises inserting the one or more structural rods into the openings.

[0063] Clause 15. The method of clauses 10-14, further comprising forming the mesh member into a desired shape following embedding one or more structural rods into the mesh member.

[0064] Clause 16. A method including: forming a mesh member, the mesh member comprising a set of filaments of a polymeric material, at least two members of the set of filaments being looped and interconnected; and attaching a trim cover to the mesh member by securing the trim cover to one or more anchors embedded within the mesh member.

[0065] Clause 17. The method of clause 16, wherein attaching the trim cover to the one or more anchors includes attaching the trim cover to the one or more anchors via connectors extending from the trim cover through openings defined by the mesh member and engaging the one or more anchors.

[0066] Clause 18. The method of clauses 16-17, further comprising embedding one or more anchors in the mesh member before attaching the trim cover to the mesh member.

[0067] Clause 19. The method of clauses 16-18, further comprising, following embedding the one or more anchors in the mesh member, forming the mesh member into a desired shape before attaching the trim cover to the mesh member.

[0068] Clause 20. The method of clauses 16-19, further comprising forming openings along a bottom of the mesh member, and wherein embedding the one or more anchors in the mesh member comprises inserting the one or more anchors into the openings.

[0069] It is understood that first, second, third, fourth, etc. designations for any component, state, or condition described herein may be rearranged within the claims so as to be in chronological order with respect to the claims. Furthermore, it is understood that any component, state, or condition described herein that does not have a numerical designation may be given a first, second, third, fourth, etc. designation in the claims if one or more of the particular components, states, or conditions are claimed.

[0070] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms according to the present disclosure. In that regard, it should be understood that the terms used herein are terms of description rather than limitation, and that various changes may be made without departing from the spirit and scope of the present disclosure. Furthermore, features of various embodiments may be combined to form further embodiments according to the present disclosure.

Claims

1. a mesh member comprising a set of filaments of a polymeric material, at least two members of the set of filaments being looped and bonded to one another; a structural framework embedded within the mesh member, wherein the structural framework has a stiffness greater than the stiffness of the mesh member.

2. The article of manufacture of claim 1 further comprising a trim cover disposed over the exterior of said mesh member and secured to said structural framework.

3. 3. The article of manufacture of claim 2, further comprising a connector extending from the trim cover and through an opening defined by the mesh member to engage the structural framework to secure the trim cover to the structural framework.

4. The article of manufacture of claim 2 , wherein the trim cover is attached to the structural framework via clips or hog rings.

5. The article of manufacture of claim 1 , wherein the structural framework is attached to the filaments by overmolding the filaments onto the structural framework.

6. The article of manufacture of claim 1 , wherein the structural framework is disposed within openings defined by the mesh member.

7. The article of manufacture of claim 6 , wherein the opening defined by the mesh member is located on an opposite side of the mesh member relative to a trim cover.

8. The article of claim 1 , wherein the article is a vehicle seat bottom.

9. The article of manufacture of claim 1 , wherein the article is a seat back for a vehicle.

10. forming a mesh member, the mesh member comprising a set of filaments of a polymeric material, at least two members of the set of filaments being looped and bonded to one another; embedding one or more structural rods in the mesh member, wherein a stiffness of the one or more structural rods is greater than a stiffness of the mesh member.

11. The method of claim 10 further comprising attaching a trim cover to the exterior of the mesh member.

12. The method of claim 11 , wherein attaching the trim cover to the exterior of the mesh member comprises fastening the trim cover to the one or more structures.

13. 13. The method of claim 12, wherein securing the trim cover to the one or more structural rods comprises attaching the trim cover to the one or more structural rods via connectors that extend from the trim cover through openings defined by the mesh member and engage with the one or more structural rods.

14. 11. The method of claim 10, further comprising forming openings along a bottom of the mesh member, and wherein embedding the one or more structural rods in the mesh member comprises inserting the one or more structural rods into the openings.

15. The method of claim 10 , further comprising forming the mesh member into a desired shape following embedding the one or more structural rods into the mesh member.

16. forming a mesh member, the mesh member comprising a set of filaments of a polymeric material, at least two members of the set of filaments being looped and bonded to one another; and attaching the trim cover to the mesh member by fastening the trim cover to one or more anchors embedded within the mesh member.

17. 17. The method of claim 16, wherein attaching the trim cover to the one or more anchors comprises attaching the trim cover to the one or more anchors via connectors that extend from the trim cover through openings defined by the mesh member and engage the one or more anchors.

18. 17. The method of claim 16, further comprising embedding the one or more anchors into the mesh member before attaching the trim cover to the mesh member.

19. 20. The method of claim 18, further comprising, following embedding the one or more anchors in the mesh member, forming the mesh member into a desired shape prior to attaching the trim cover to the mesh member.

20. 20. The method of claim 18, further comprising forming openings along a bottom of the mesh member, and wherein embedding the one or more anchors in the mesh member comprises inserting the one or more anchors into the openings.

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