Method and apparatus for manufacturing cushions

Abstract

Cushions, seating assemblies, devices and methods for making them are disclosed. The methods may include heating a polymeric material to a molten state to become a molten polymer. The molten polymer may then be introduced into various embodiments of a die plate, such as a die plate having a first region and a different second region. For example, one region may have more open regions with open and closed portions. In another embodiment, the die plate may include slits to produce a film. A heating device may heat the molten filament after it exits the die plate. In yet another embodiment, the cushion may be made from a body of entangled and / or entangled polymeric filaments and a bolster attached thereto. In yet another embodiment, the die may be configured to provide a cushion with regions of different hardness.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application is a continuation-in-part of U.S. Patent Application No. 17 / 741,639, filed May 11, 2022, and claims the benefit of U.S. Provisional Patent Application No. 63 / 353,728, filed June 20, 2022, U.S. Provisional Patent Application No. 63 / 357,163, filed June 30, 2022, U.S. Provisional Patent Application No. 63 / 357,222, filed June 30, 2022, U.S. Provisional Patent Application No. 63 / 356,539, filed June 29, 2022, and U.S. Provisional Patent Application No. 63 / 356,526, filed June 29, 2022, the disclosures of which are incorporated herein by reference in their entireties.

[0002] (Technical field) The present disclosure relates to methods and apparatus for manufacturing interior components, such as non-foam cushions for seat assemblies that may be used in vehicles.

[0003] For a further understanding of the nature, objects and advantages of the present disclosure, reference should be made to the following detailed description read in conjunction with the following drawings, in which like reference numerals indicate like elements and in which: [Brief description of the drawings]

[0004] [Figure 1] FIG. 1 shows a schematic diagram of a system and method according to an embodiment described herein. [Diagram 2] FIG. 2 shows a die plate that can be used as part of the process shown in FIG. [Diagram 3] FIG. 3 illustrates a die plate apparatus according to an embodiment described herein. [Figure 4] FIG. 4 illustrates another die plate apparatus according to embodiments described herein. [Diagram 5] FIG. 5 illustrates a cushion blank forming a portion of a vehicle interior component according to embodiments described herein. [Figure 6]FIG. 6 illustrates a die plate apparatus and funnel that can be used as part of the methods according to embodiments described herein. [Figure 7] FIG. 7 is a front perspective view of a vehicle seat assembly according to one embodiment. [Figure 8] FIG. 8 is a front schematic view of a system for manufacturing a seat cushion for the seat assembly of FIG. [Figure 9] FIG. 9 is a top perspective view of a tool plate of the system of FIG. 8 in accordance with one embodiment. [Figure 10] FIG. 10 is a partial top perspective view of the system of FIG. [Figure 11] FIG. 11 is a top perspective view of a tool die of the system of FIG. 8 according to one embodiment. [Figure 12] FIG. 12 is a partial front perspective view of a cushion of the seat assembly of FIG. 7 according to one embodiment. [Figure 13] FIG. 13 is a top plan view of the tool plate of the system of FIG. [Figure 14] FIG. 14 is a side view of multiple filaments and multiple films of the system of FIG. [Figure 15] FIG. 15 is an enlarged front perspective view of the system of FIG. [Figure 16] FIG. 16 illustrates a portion of a system including a heating device according to embodiments described herein. [Figure 17] FIG. 17 illustrates the application of a heating device to a polymer filament according to embodiments described herein. [Figure 18] FIG. 18 illustrates a cross section of a vehicle interior part manufactured according to embodiments described herein. [Figure 19] FIG. 19 shows a schematic perspective view of a seat cushion or seat back according to one embodiment. [Figure 20] FIG. 20 shows a schematic cross-sectional front view of the seat assembly of FIG. [Figure 21] FIG. 21 illustrates diagrammatically components used in the method of FIG. 1 according to another embodiment. [Figure 22]FIG. 22 is a perspective view of one embodiment of a seat assembly with the trim cover and a portion of the cushion removed. [Diagram 23] FIG. 23 is a perspective view of one embodiment of a non-foam / non-foam cushion. [Figure 24] FIG. 24 is a schematic diagram of one embodiment of a non-foam / non-foam cushion with variable firmness / bulk density / filament size. [Diagram 25] FIG. 25 is a schematic diagram of another embodiment of a non-foam / non-foam cushion having a firmness / bulk density / average filament size gradient. [Figure 26] FIG. 26 is a perspective view of one embodiment of a resin dispensing breaker plate used to make non-foam / no-foam cushions. [Figure 27] FIG. 27 is a cross-sectional side view of one embodiment of a manufacturing system. [Figure 28] FIG. 28 is a flow diagram illustrating one embodiment of a method for using a breaker plate to manufacture a variable non-foam cushion. [Figure 29] FIG. 29 is a top view of another embodiment of a resin dispensing breaker plate used to make non-foam / no-foam cushions. [Diagram 30] 30 is a cross-sectional view of a portion of the breaker plate of FIG. [Diagram 31] FIG. 31 is an enlarged view of one of the orifices of the breaker plate of FIG. [Diagram 32] FIG. 32 is a flow chart of a manufacturing method for a vehicle interior part. [Diagram 33] FIG. 33 is a flow diagram of a method for manufacturing a product. [Diagram 34] FIG. 34 is a flow diagram of a method for manufacturing a product. [Diagram 35] FIG. 35 is a flow diagram of a method for assembling the seat. [Diagram 36] FIG. 36 is a flow chart of a method for manufacturing a product. [Figure 37] FIG. 37 is a flow chart of a manufacturing method for a vehicle interior part. [Figure 38]FIG. 38 is a flow chart of a manufacturing method for a vehicle interior part. [Figure 39] FIG. 39 is a flow chart of a manufacturing method for a vehicle interior part. [Diagram 40] FIG. 40 is a flow diagram of a method for manufacturing a product such as a seat cushion. [Diagram 41] FIG. 41 is a flow chart of a method for manufacturing a seat pad. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] 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 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.

[0006] It is to be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The figures 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 details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art how to variously use the embodiments according to the disclosure.

[0007] It should also be understood that, although terms such as first, second, etc. are used in some instances herein to describe various elements, 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 called a second contact, and similarly, a second contact can be called a first contact, without departing from the scope of the various embodiments described. Although a first contact and a second contact are both contacts, they are not the same contact.

[0008] The terms used in the description of various embodiments herein are intended to describe only certain embodiments and are not intended to be limiting. As used in the description of various embodiments and the appended claims, the singular form is intended to include the plural form unless the context clearly indicates otherwise. The terms "comprises," "has," "consists of," or "has" as used herein specify the presence of stated features, integers, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

[0009] As used herein, the term "if" is to be interpreted to mean "when" or "upon" or "upon determining" or "upon detecting," depending on the context, as appropriate. Similarly, the term "if determined" or "if (a described condition or event) is detected" is to be interpreted to mean "upon determining" or "upon determining" or "upon detecting (a described condition or event)," depending on the context, as appropriate.

[0010] Except where expressly indicated in the examples or otherwise, all numerical values ​​herein indicating amounts of materials or conditions of reaction and / or use should be understood as modified by the term "approximately" in describing the broadest scope of the disclosure. Practice within the stated numerical limits is generally preferred. Also, unless expressly indicated to the contrary, percent, "parts" and ratio values ​​are by weight. The term "polymer" includes "oligomers", "copolymers", "terpolymers", and the like. Molecular weights listed for polymers refer to weight average molecular weights unless otherwise indicated. The description of a group or type of material as suitable or preferred for a given purpose in the context of the disclosure also implies that mixtures of any two or more members of that group or type are equally suitable or preferred. The description of components by chemical terms refers to the components upon addition to any combination specified in the description and does not necessarily exclude chemical interactions between the components of the mixture once mixed. The initial definition of an acronym or other abbreviation applies to all subsequent uses in this specification of the same abbreviation, mutatis mutandis, to normal grammatical variations of the abbreviation originally defined. Unless expressly stated to the contrary, measurements of a property are determined by the same techniques as previously or subsequently referenced for the same property.

[0011] As used herein, the term "and / or" means that all or only one of the elements of the group may be present. For example, "A and / or B" means "A only, B only, or both A and B." In the case of "A only," the term also includes the possibility that B is not present, i.e., "A only and not B."

[0012] It is also to be understood that the disclosure is not limited to the specific embodiments and methods described below, as specific components and / or conditions may, of course, vary. Further, the terminology used herein is used only for the purpose of describing particular embodiments of the disclosure, and is not intended to be limiting in any way.

[0013] With respect to the terms "comprising," "consisting of," and "consisting essentially of," when one of these three terms is used in this specification, the subject matter of this disclosure may include the use of either of the other two terms.

[0014] The terms "substantially," "generally," or "about" may be used to describe embodiments disclosed or claimed herein. The term "substantially" may modify a value or relative characteristic disclosed or claimed in this disclosure. In such cases, "substantially" may mean that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of the value or relative characteristic.

[0015] It should also be understood that a range of integers explicitly includes all integers therebetween. For example, the range of integers 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range of 1 to 100 includes 1, 2, 3, 4, ... 97, 98, 99, 100. Similarly, when any range is called out, the numbers in between that are increments of the difference between the upper and lower limits divided by 10 can be alternative upper or lower limits. For example, if the range is 1.1 to 2.1, the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits.

[0016] Filaments or threads can be used herein to refer to generally linear polymer units (although they may be fused together to form a network) after being discharged through one or more orifices of a die, plate, die plate, tool, tool plate, extrusion die, or breaker plate, and they are similarly used to refer to equivalent components. Similarly, the terms: connected filament structure, filament structure, yielding thread, body, network, final member, non-foam component, non-woven network, or cushion can refer to the same or similar components. The terms funnel and cover can be used to refer to the same or similar components. The description herein can also use various terms to refer to holes, such as holes, orifices, nozzles, openings, etc. In yet another example, tanks, water tanks, cooling chambers, liquid tanks, and vats can refer to the same or similar components. The use of different terms to refer to the same or similar components can be used to avoid confusion in describing different preferred embodiments. The terms are interchangeable because the various components of the features of the various embodiments can be combined in ways not explicitly described herein. This does not detract from the fact that certain terms may provide specific details not included in other interchangeable terms unless expressly stated otherwise (e.g., a water tank and a liquid tank refer to similar interchangeable components, but in at least one preferred embodiment, when a water tank is used, the tank is filled with water or configured to be filled with water as opposed to liquid).

[0017] More specifically, the term interconnect refers to separate polymer filaments that are entangled, entangled, bonded, or otherwise joined together to form a mesh, however, interconnect does not refer to polymer filaments that are manufactured separately and then secured together by fasteners or threads.

[0018] Referring to FIG. 1, a schematic diagram of a system 10 usable with a method 11 according to embodiments described herein is shown. A hopper 12 holds solid granules of polymeric material 14 to be extruded. In this embodiment, the material 14 is linear low density polyethylene (LLDPE), however, the methods described herein can desirably and effectively use different types of polymers to produce a final product. The material 14 is fed from the hopper 12 to an extruder 16. The extruder 16 melts the material 14 and delivers it to a die plate apparatus 18 including a die plate 20. The extruder 16 may be, for example, a conventional extruder including a barrel that receives a rotatable screw. The rotation of the screw pushes and moves the material 14 through the barrel, helping to heat the material due to friction generated as the screw rotates. A heating element may be disposed in the barrel to heat the polymeric material 14 within the barrel.

[0019] The material 14 exits the extruder 16 under pressure at location 22 in a molten state. Unless otherwise stated, the term "molten" as used herein means that the material is at least partially melted. This does not mean that the material is necessarily in a completely liquid state. Rather, it means that the material is not completely solid and can still flow through the elements of the system 10. For example, the molten material can still flow through the die plate 20, but may be very viscous and begin to solidify. The solid granules of polymeric material 14 are melted in the extruder 16, but as the material is no longer agitated by the extruder screw and moves away from the heater, it begins to cool. At different points in the process 11, the material may have a higher or lower viscosity, but the term "molten" applies herein when the material is still partially melted and can flow (even if slowly).

[0020] The die plate 20 extrudes the material 14 into filaments 24. More specifically, the die plate 20 has a plurality of holes 21 (see, e.g., FIG. 2 ) disposed therethrough through which the molten material 14 passes. A single filament 24 is extruded from each of the die plate holes. The filaments 24 fall downward from the die plate 20 into a funnel 26 due to system pressure and gravity. The funnel 26 helps link or group the filaments 24 into a more compact arrangement in which the filaments 24 bend or loop and each filament 24 contacts and is bonded to at least one other filament 24. In this embodiment, the funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. More specifically, the funnel 26 has a narrower funnel outlet 30 than the funnel inlet 28. Separate individual filaments 24 enter funnel inlet 28, then as they accumulate and slide down funnel 26 toward funnel outlet 30, they bend or loop and move in contact with one another, and the connected filament structure 32 exits funnel outlet 30 and enters water tank 34. As the filaments 24 reach funnel 26, those filaments near the outer portion of funnel 26 (approximately two to three rows) slide down the sloping face of funnel 26, thereby forming a skin on connected filament structure 32.

[0021] The water tank 34 holds water 36 and receives the connected filament structure 32 from the funnel 26. The water 36 serves at least two functions. First, it temporarily supports the connected filament structure 32, helping to prevent it from collapsing or condensing into a less open or less porous arrangement. As such, the water 36 provides some resistance to further induce bends and loops in the filaments 24, further building up the connected filament structure 32. Second, the water 36 externally cools the polymer filaments 24, causing them to solidify. The temperature of the water 36 may be much lower than the temperature of the filaments 24 as they exit the die plate 20, for example, the temperature of the ambient environment surrounding the tank 34. The fluid used in this embodiment is liquid water 36, although other types of fluids may be used in other embodiments.

[0022] The water tank 34 includes various rollers and conveyors that aid in moving the connected filament structure 32 through and out of the water 36. The tow conveyor 38 is submerged in the water 36 and engages both sides of the connected filament structure 32 to move it away from the funnel 26 at approximately the same speed as it exits the funnel 26. The gap between the opposing portions of the tow conveyor 38 is slightly narrower than the width of the connected filament structure 32 so that the tow conveyor 38 can better grip the connected filament structure 32. As previously mentioned, FIG. 1 is a schematic diagram and has been simplified for illustrative purposes. For example, conveyors such as the tow conveyor 38 may be positioned to extend from the front to the back of the system 10 in FIG. 1, rather than from side to side as shown.

[0023] Additional rollers 40 help guide the connected filament structure 32, while it remains submerged, through the water 36 toward a conveyor belt 42 and a shaking table 44 located outside the water tank 34. The shaking table 44 shakes the connected filament structure 32 while it is on the conveyor belt 42 to remove at least a portion of the water 36. Pressurized air may be blown toward the connected filament structure 32, and the connected filament structure 32 may be compressed to remove more of the water 36. Finally, the connected filament structure 32 may be cut to the desired size and shape.

[0024] As mentioned above, the filament structure 32 forms a threaded net-like material that can be used, for example, as a cushion blank for a portion of a vehicle interior part. In some cases, the filament structure 32 may have a rectangular cross-section and may later be cut or shaped to a desired contour for its intended use. As shown in FIG. 2, a die plate such as the die plate 20 may itself be rectangular and may have a plurality of holes 21 (only some of which are labeled in FIG. 2 for clarity) of uniform diameter and "hole density". "Hole density" as used in this context is the number of holes per unit area in the die plate 20. In some applications, it may be desirable to have a filament structure that does not have a rectangular cross-section or has parts that have a higher or lower density than other parts. In some embodiments, both of these features may be combined.

[0025] FIG. 3 illustrates a die plate apparatus 46 that can be used, for example, in the method described in connection with FIG. 1. The die plate apparatus 46 includes a die plate 48 and a template 50. The die plate 48 is rectangular. However, the template 50 has a predetermined contour portion 51, which in this embodiment is the inner periphery of the template 50. The template 50 is used to shield a portion of the die plate 48 to provide a filament structure having a cross-section defined by the predetermined contour portion 51, for example, a cushion blank for a vehicle seat. In addition to providing filament structures having a non-rectangular cross-section, the die plate arrangement 46 also provides filament structures having a plurality of different densities. As used in this context, the "density" of a filament structure refers to the amount of material per volume. For example, in a vehicle seat, the seat bottom can include bolsters on the inner and outer sides of the seat. It may be desirable for the bolsters to be somewhat harder than the center portion of the seat bottom where the passenger sits. One way to achieve this is to increase the density of the filament material in the bolster area compared to the density of the filament material in the center portion of the cushion.

[0026] As discussed above, the die plate 20 shown in FIG. 1 includes holes of uniform diameter and hole density. In contrast, the hole density in the die plate 48 shown in FIG. 2 is not uniform. Rather, the die plate 48 includes a first region 54, shown in FIG. 3, as indicated by a curved dashed line toward the left side of the figure. In this embodiment, the die plate 48 includes another region of the first region 54, shown in FIG. 3, as indicated by a curved dashed line toward the right side of the figure. As will be described in more detail below, the two first regions 54 are positioned in positions corresponding to the left and right bolster regions of the seat cushion. The die plate 48 also includes a second region 56, shown in FIG. 3, as indicated by a rectangular dashed line. It will be understood that the shapes of the first region 54 and the second region 56 can be different in different embodiments depending on the desired end product.

[0027] As shown in FIG. 3, each of the first regions 54 includes a plurality of first holes 58, and the second region 56 includes a plurality of second holes 60. In each case, for clarity, only some of the holes 58, 60 are labeled in FIG. 3. However, it is understood that each of the first region 54 and the second region 56 may include tens, hundreds, or even more of the first holes 58, 60. The plurality of first holes 58 together define an open space in the first region 54. This open space, compared to the total area of ​​the first region 54, defines the open space per unit area in the first region 54. In other words, the first region 54 has a closed portion defined by the die plate material and an open portion defined by all of the first holes 58. The total open area defined by the first holes 58 constitutes a portion of the first region 54, and when this total open area is divided by the total area occupied by the first region 54, a number is obtained that can be considered the "open space per unit area." This open space per unit area can then be referred to as the "first open space per unit area" since it is within the first region 54. Similarly, the total open area defined by the second holes 60 in the second region 56 defines a second open space per unit area. In the embodiment shown in FIG. 3, the first open space per unit area is greater than the second open space per unit area, resulting in a higher density of filament material in the first region 54 compared to the second region 56.

[0028] As mentioned above, another way to consider the concept of "open space per unit area" is to define a ratio, specifically the ratio of the open area to the total area in each of the first region 54 and the second region 56. Stated differently, the ratio of the open area of ​​the first region, i.e. the total open area defined by the first holes 58, to the first region 54 (total) is greater than the ratio of the open area of ​​the second region to the second region 56 (total). To achieve the difference in hole density between the first region 54 and the second region 56, several different methods can be used. For example, in one embodiment, the diameters of the holes 58, 60 may be the same, but the number of first holes 58 per unit area in the first region 54 may be different from the number of second holes 60 per unit area in the second region 56. More specifically, the number of first holes 58 per unit area in the first region 54 may be greater than the number of second holes 60 per unit area in the second region 56. Alternatively, the number of first holes 58 per unit area may be the same as the number of second holes 60 per unit area, but the first holes 58 may have a diameter greater than the diameter of the second holes 60. In either case, the total amount of polymeric material per unit area flowing through the first regions 54 will be greater than the total amount of material per unit area flowing through the second regions 56. The greater amount of material results in a filament structure having a higher density in the first regions 54 than in the second regions 56.

[0029] FIG. 4 illustrates a die plate apparatus 62 according to an embodiment described herein. Similar to the die plate apparatus 46 illustrated in FIG. 3, the die plate apparatus 62 includes a die plate 64 and a template 66 configured to cover or mask a portion of a plurality of holes in the die plate 64. The template 66 has a predetermined contour portion 67 that defines a cross-section of a final product, for example, a cushion for a vehicle seat. The die plate 64 includes a first region 70 and a second region 71 similar to those illustrated in the die plate 48 of FIG. 3. Also similar to the die plate 48, the first region 70 and the second region 72 of the die plate 64 include a first hole 74 and a second hole 76, respectively. However, one difference from the die plate 64 is the inclusion of a third region 78, which is indicated by the dashed lines defining a small rectangle in FIG. 4.

[0030] The third portion 78 includes a plurality of third holes 81 disposed therethrough. Again, only some of them are labeled with reference numbers for clarity. The plurality of third holes 81 together define a third open space per unit area of ​​the third region 78. In this embodiment, the third open space per unit area is smaller than the second open space per unit area. In other words, the filament structure created using the die plate apparatus 62 has a lower density in the third region 78 than in the second region 71. This may be a convenient location for placing an occupant sensor such as a seat belt reminder (SBR). The density of the third holes 81 in the third region 78 may also be defined as described above. That is, in the third region 78, the ratio of the open area to the entire third region 78 is smaller than the ratio of the open area of ​​the second region 71 to the entire second region 71. The die plate apparatus 62 includes a third region 78 and first and second regions 70, 71, although in other embodiments it may not include a first region 70 of high density and may only include a third region 78 of low density within the second region 71.

[0031] FIG. 5 illustrates a filament structure 82 manufactured as described above in connection with FIG. 1 using a die plate apparatus such as the die plate apparatus 62 illustrated in FIG. 4. The filament structure 82 includes three regions, each corresponding to a respective region of the die plate 64. More specifically, the filament structure 82 includes two first regions 70', where a prime (') is used in the reference numerals to indicate the corresponding regions from the die plate 64 illustrated in FIG. 4. The first regions 70' are the densest regions in the filament structure 82 and correspond to the left and right bolsters of a vehicle seat cushion. As illustrated in FIG. 5, the filament structure 82 is illustrated as a front cross-sectional view of a seat bottom cushion blank. As illustrated in FIG. 5, the filament structure 82 has a cross-section 68' that generally conforms to the predetermined contour portion 68 of the template 66 illustrated in FIG. 4. In the filament structure 82, the second regions 72' are less dense than the first regions 70', which may provide a softer feel and greater comfort to a seated occupant. The third region 78' is the least dense and provides a location for an SBR or other occupant sensor. It is important that this region be particularly soft so that it can easily flex to activate the sensor, even for light occupants.

[0032] To maintain the desired shape of the final product, a die plate apparatus such as die plate apparatus 46 can be combined with a funnel having a corresponding geometric configuration (see, for example, funnel 26 shown in FIG. 1). For example, FIG. 6 illustrates die plate apparatus 46 including die plate 48 and template 50. As described above in connection with FIG. 1, molten polymer can be forced through openings in die plate 48 to produce filaments 84 of material that will form the final product after cooling. FIG. 6 illustrates funnel 86 that also includes a template 88 configured similarly to template 50 used with die plate 48. Template 88 used with funnel 86 helps ensure that the desired shape of the final product is maintained as filaments 84 fall from die plate 48 through funnel 86.

[0033] A method 650 for manufacturing a vehicle interior part is described. The method 650 includes heating 652 a polymeric material (e.g., 14) to a molten state such that the polymeric material becomes a molten polymer (as shown in FIG. 1).

[0034] The method 650 includes introducing 654 molten polymer to a die plate (e.g., 20, 48, and / or 64) having a first region (e.g., bolster region 54) including a plurality of first holes (e.g., 58) extending therethrough, and a second region (e.g., cushion region 56) including a plurality of second holes (e.g., 60) extending therethrough. The plurality of first holes (e.g., 58) together define a first open volume per unit area in the first region (e.g., 54), and the plurality of second holes (e.g., 60) together define a second open volume per unit area in the second region (e.g., 56), the first open volume per unit area being greater than the second open volume per unit area (i.e., the density of the bolster region is different / higher than the density of the cushion region; e.g., the holes in the first region (e.g., 54) allow more material to pass through than the holes in the second region).

[0035] The method 650 includes cooling 656 the molten polymer exiting the die plate (eg, 20, 48, and / or 64).

[0036] In some embodiments, the number of first holes (e.g., 58) per unit area in the first region (e.g., 54) is greater than the number of second holes (e.g., 60) per unit area in the second region (e.g., 56).

[0037] In some embodiments, the first hole (eg, 58) has a larger diameter than the second hole (eg, 60).

[0038] In some embodiments, a cushion blank is produced by cooling the polymer exiting the die plate (e.g., 20, 48, and / or 64), and the method further includes shielding a portion of the die plate (e.g., 20, 48, and / or 64) with a template having a predetermined contour such that the cushion blank has a cross-section defined by the predetermined contour.

[0039] In some embodiments, the second region (e.g., 56) includes a location in the cushion blank that corresponds to the location of an occupant sensor (e.g., a low-density region located adjacent to an occupant sensor that activates a seat belt reminder).

[0040] In some embodiments, the die plate (e.g., 20, 48 and / or 64) includes two first regions (e.g., 54), each positioned in a location corresponding to a respective bolster region of the cushion blank.

[0041] In some embodiments, the die plate (e.g., 20, 48 and / or 64) includes a third region (e.g., 78) including a plurality of third holes (e.g., 81) therethrough, the plurality of third holes (e.g., 81) together defining a third open space per unit area in the third region (e.g., 78), the third open space per unit area being smaller than the second open space per unit area.

[0042] In some embodiments, the vehicle interior part is formed by any of the methods described above.

[0043] A method 650 for manufacturing a vehicle interior part is described. The method 650 includes heating a polymeric material (eg, 14) to a molten state such that the polymeric material becomes a molten polymer.

[0044] The method 650 includes introducing 652 molten polymer to a die plate (e.g., 20, 48 and / or 64) including a first region (e.g., 54) having an open portion and a closed portion and a second region (e.g., 56) having an open portion and a closed portion, wherein a ratio of the open portion of the first region (e.g., 54) to the first region (e.g., 54) is greater than a ratio of the open portion of the second region (e.g., 56) to the second region (e.g., 56).

[0045] The method 650 includes cooling 654 the molten polymer exiting the die plate (eg, 20, 48, and / or 64).

[0046] In some embodiments, the first region (e.g., 54) includes a plurality of first holes (e.g., 58) that define an open portion of the first region (e.g., 54), and the second region (e.g., 56) includes a plurality of second holes (e.g., 60) that define an open portion of the second region (e.g., 56), and the number of first holes (e.g., 58) per unit area in the first region (e.g., 54) is greater than the number of second holes (e.g., 60) per unit area in the second region (e.g., 56).

[0047] In some embodiments, the first region (e.g., 54) includes a plurality of first holes (e.g., 58) that define an open portion of the first region (e.g., 54), and the second region (e.g., 56) includes a plurality of second holes (e.g., 60) that define an open portion of the second region (e.g., 56), and the first holes (e.g., 58) have a larger diameter than the second holes (e.g., 60).

[0048] In some embodiments, the vehicle interior component includes a cushion blank having a cross-section, and the method further includes shielding a portion of the die plate (e.g., 20, 48 and / or 64) with a template having a contour that defines the cross-section of the cushion blank.

[0049] In some embodiments, the die plate (e.g., 20, 48 and / or 64) includes a plurality of first regions (e.g., 54), each of the plurality of first regions positioned in a position corresponding to a respective bolster region of the cushion blank.

[0050] In some embodiments, the second region (eg, 56) includes a location within the cushion blank configured to receive an occupant sensor.

[0051] In some embodiments, the die plate (e.g., 20, 48 and / or 64) further includes a third region (e.g., 78) having an open portion and a closed portion, and the ratio of the open portion of the second region (e.g., 56) to the second region (e.g., 56) is greater than the ratio of the open portion of the third region (e.g., 78) to the third region (e.g., 78).

[0052] A die plate apparatus usable for manufacturing a vehicle interior part is described, the die plate apparatus including a plate including a first region (e.g., 54) including a plurality of first holes (e.g., 58) extending therethrough, and a second region (e.g., 56) including a plurality of second holes (e.g., 60) extending therethrough, the plurality of first holes (e.g., 58) together defining a first open portion in the first region (e.g., 54), the plurality of second holes (e.g., 60) together defining a second open portion in the second region (e.g., 56), and a ratio of the first open portion to the first region (e.g., 54) being greater than a ratio of the second open portion to the second region (e.g., 56).

[0053] In some embodiments, the number of first holes (e.g., 58) per unit area in the first region (e.g., 54) is greater than the number of second holes (e.g., 60) per unit area in the second region (e.g., 56).

[0054] In some embodiments, the diameter of the first hole (eg, 58) is greater than the diameter of the second hole (eg, 60).

[0055] In some embodiments, the die plate apparatus further includes a template configured to cover at least a portion of the first hole (e.g., 58), at least a portion of the second hole (e.g., 60), or at least a portion of the first hole (e.g., 58) and the second hole (e.g., 60), the template having a predetermined contour defining a cross-section of a portion of the vehicle interior part.

[0056] In some embodiments, the vehicle interior component is a seat cushion and the plate includes two first regions (e.g., 54), each of the two first regions positioned in a location corresponding to a respective bolster region of the seat cushion.

[0057] 7 illustrates the seat assembly 120 as a vehicle seat assembly 120 according to one embodiment. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be used. The seat assembly 120 may be used in a land vehicle, an aircraft, a watercraft, etc. The seat assembly 120 may also be used as an office chair, a comfort chair, etc.

[0058] The illustrated seat assembly 120 includes a seat bottom cushion 122 for supporting the pelvis and thighs of a seated occupant. The seat assembly 120 also includes a seat back cushion 124 for supporting the back and shoulders of a seated occupant. The trim cover 26 is disposed over the seat cushions 122, 124 to hide the cushions 122, 124 and to provide a uniform, smooth contact surface for the occupant.

[0059] Referring to FIG. 8, the seat cushions 122, 124 are manufactured from a system 127 and process of extruded thermoplastic resin network. In the illustrated embodiment, an extruder 128 delivers pressurized molten thermoplastic resin to an extrusion die 130. The extrusion die 130 is configured with a plurality of exit ports or nozzles 132 for discharging a plurality of strands 134 of molten thermoplastic resin. The strands 134 are discharged through a tool 136 into a fluid chamber 138. The tool 136 guides the strands 134 into the fluid chamber 138. The fluid chamber 138 may hold a fluid, such as water, that provides resistance and cooling to the strands 134. The fluid chamber 138 provides resistance to the flow of the strands 134, thereby causing the strands 134 to bend, loop, and cross over adjacent strands 134 within a contour defined by the tool 136. The strands 134 may also expand and float within the fluid chamber 138. The strands 134 are cooled within the fluid chamber 138 by the fluid to form a unitary nonwoven thermoplastic cushion 122. According to this process, the nonwoven thermoplastic cushion 122 is imparted resistance to the fluid, cooled, and solidified.

[0060] 9 and 10 show the tool 136 as a plate 136 called a funnel plate 136. An opening 140 is formed through the plate 136 to guide the thermoplastic resin threads 134 into a cooling chamber 138 and through a funnel. The opening 140 is sized to match the overall contour or perimeter of the seat bottom cushion 122 as viewed in the front-to-rear direction designated by reference character Z in FIG. 7. The molten resin threads 134 are thus collected, guided, and cooled into a cushion 122 having the overall contour of the seat cushion 122. The plate 136 forms a network of the molten resin threads 134 into the overall contour of the cushion 122 as the threads 134 bend, loop, and cross. The plate 136 forms the network, which then solidifies into the nonwoven network assembly of the cushion 122.

[0061] The through opening 140 is provided with a curvature to form the nonwoven cushion 122 with a curvature. For example, the through opening 140 has a generally convex contour to form a concave surface 142 on the upper surface of the cushion 122 as a central seating surface. The through opening 140 may be provided with a fillet or chamfer around the opening 140 at the input end of the plate 136. The fillet may have a radius of at least 12 millimeters, or the chamfer may measure 12 millimeters by 12 millimeters. The fillet or chamfer provides a leading edge around the opening 140 to guide the thread 134 into the plate opening 140.

[0062] The seat cushions 122, 124 are often molded from foam materials. Foam cushions require dedicated tooling to mold each cushion part. In contrast to prior art molding tools, the seat cushion 122 has a dedicated tooling plate 136. The system 127 includes a flexible apparatus suitable for manufacturing a variety of cushions with a variety of tooling plates. The extrusion die 130 includes a number of nozzles 132 that exceed the total area of ​​the through opening 140. When used with the tooling plate 136, the nozzles outside the perimeter of the through opening 140 are closed so that the extruded threads 134 are discharged only into the opening 140. The opening and closing action of each nozzle 132 can be adjusted for each tooling plate 136.

[0063] The tooling plate 136 induces a shape into the cushion 122, after which the threads 134 cool, harden, and solidify into a nonwoven mesh cushion material. Secondary molding operations to form the shape, contour, seating, and connecting surfaces can be eliminated. The cushion 122 is cut from an otherwise continuously formed mesh assembly. Alternatively, the cushion 122 may be formed from multiple mesh assembly sections having a continuously transitioning overall contour that are interlocked within the trim cover 126. The sections can be glued or otherwise secured together.

[0064] The tool plate 136 may have a suitable thickness greater than 12 millimeters. For example, the tool plate 136 may have a thickness of at least 1 inch (25.4 mm). Referring now to FIG. 11 , the tool 136 may be a tunnel die 144 that is thicker than the tool plate 136. In the illustrated example, the die 144 has a thickness of 6 inches (152.4 mm). The die 144 includes through holes 140 formed through the thickness of the die 144 for directing the molten thermoplastic resin filaments 134 into the fluid chamber 138.

[0065] The mold 144 also includes a number of cooling passages 146 formed within the body of the mold 144, as shown in FIG. 11. The cooling passages 146 extend toward the through openings 140 to allow a coolant to cool the mold 144 and, in turn, cool the mesh material within the cavities of the openings 140. The mold 144 may extend into the fluid of the chamber 138 such that the mold 144 is cooled by the fluid of the chamber 138, which may also be disposed within the openings 140 to cool and form the nonwoven mesh. The cooling of the mold 144 initiates the cooling of the mesh filaments 134 and the formation of the shape of the cushion 122 while the filaments 134 and fluid are within the cavities of the openings 140 of the mold 144. The cooling of the mold 144 also maintains the mold 144 at a suitable temperature during repeated molding cycles of multiple mesh assemblies. According to one embodiment, the cooling passages 146 do not intersect with the through openings 140. According to another embodiment, the cooling passages 146 intersect the through openings 140 and allow fluid to pass from the cooling passages to the cavities within the through openings 140 .

[0066] A method 150 of manufacturing a product is described. The method 150 includes dispensing 152 molten thermoplastic resin through a tool (e.g., 136) having an opening (e.g., 140) sized to fit a circumference of the product, the tool (e.g., 136) producing a plurality of filaments (e.g., 134) through the tool opening (e.g., 140) while maintaining the plurality of filaments (e.g., 134) within the circumference of the product.

[0067] The method 150 includes bending 154 the strands (e.g., 134) by providing resistance to the flow of the plurality of strands (e.g., 134), such that the bent strands (e.g., 134) intersect as a single nonwoven body in the shape of a periphery of the product.

[0068] In some embodiments, the method 150 includes cooling 156 the multiple strands (eg, 134) as a single nonwoven product.

[0069] In some embodiments, the method 150 ejects molten thermoplastic resin from multiple nozzles that collectively have an area larger than the area of ​​the opening (e.g., 140) and closes a subset of the multiple nozzles outside the area of ​​the opening (e.g., 140).

[0070] In some embodiments, the method 150 includes providing a die plate as a tool (eg, 136).

[0071] In some embodiments, the method 150 includes cooling the tool (eg, 136).

[0072] In some embodiments, the method 150 includes providing a mold (eg, 144) having an opening (eg, 140) as the tool (eg, 136).

[0073] In some embodiments, the method 150 includes providing a cooling passage (eg, 146) through the mold (eg, 144) to cool the unitary nonwoven product.

[0074] In some embodiments, the method 150 includes placing a mold (eg, 144) in a cooling fluid, which cools the unitary nonwoven product.

[0075] A product manufactured according to method 160. The method includes extruding 162 molten thermoplastic resin through a tool (e.g., 136) having an opening (e.g., 140) sized to fit a periphery of the product, the tool (e.g., 136) producing a plurality of filaments (e.g., 134) through the tool opening (e.g., 140) while maintaining 163 the plurality of filaments (e.g., 134) within the periphery of the product.

[0076] The method includes bending 164 the strands (e.g., 134) by providing resistance to the flow of the multiple strands, such that the bent strands (e.g., 134) intersect as a single nonwoven body in the shape of a perimeter of the product.

[0077] In some embodiments, the article further comprises a unitary nonwoven cushion.

[0078] In some embodiments, the product further comprises a perimeter having a concave contour.

[0079] A tool (e.g., 136) is described that includes a tool body having an opening (e.g., 140) therethrough, the opening (e.g., 140) being sized to fit a periphery of the cushion, the opening (e.g., 140) being configured to receive molten thermoplastic resin as a plurality of discharge filaments (e.g., 134).

[0080] The tool through openings (eg, 140) are configured to maintain a plurality of dispense filaments (eg, 134) within the perimeter of the cushion.

[0081] In some embodiments, the through openings (eg, 140) are molded into the seat cushion, and the through openings (eg, 140) are configured to form a unitary nonwoven cushion.

[0082] In some embodiments, the through openings (e.g., 140) have a curved shape, and the through openings (e.g., 140) are configured to form a unitary nonwoven cushion having a curve.

[0083] In some embodiments, the through openings (eg, 140) have multiple curvatures with a radius of at least 12 millimeters.

[0084] In some embodiments, the through opening (eg, 140) is formed with a convex perimeter to create a concave surface in the cushion.

[0085] A system for manufacturing a cushion is described, the system including a dispenser of molten thermoplastic resin, the system including a tool (e.g., 136) oriented relative to the dispenser to receive the molten thermoplastic resin.

[0086] In some embodiments, the system further includes a fluid chamber for receiving molten thermoplastic resin and providing resistance to the flow of the multiple discharged strands (e.g., 134) causing the strands (e.g., 134) to bend and cross as a single nonwoven body in the shape of the entire periphery of the cushion.

[0087] In some embodiments, a tool (e.g., 136) is oriented within the fluid chamber to cool the multiple discharged strands (e.g., 134) as a single nonwoven cushion.

[0088] In some embodiments, cooling passages are formed through the tool (eg, 136) to cool the multiple discharged strands (eg, 134) as a single nonwoven cushion.

[0089] 7 illustrates the seat assembly 120 as a vehicle seat assembly 120 according to one embodiment. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be used. The seat assembly 120 may be used in a land vehicle, an aircraft, a watercraft, etc. The seat assembly 120 may also be used as an office chair, a comfort chair, etc.

[0090] The illustrated seat assembly 120 includes a seat bottom cushion 122 for supporting the pelvis and thighs of a seated occupant. The seat assembly 120 also includes a seat back cushion 124 for supporting the back and shoulders of a seated occupant. A trim cover 126 is provided over the seat cushions 122, 124 to hide the cushions 122, 124 and to provide a uniform, smooth contact surface for the occupant.

[0091] 12, one of the seat cushions 122 is shown partially exploded from the seat assembly 120. The seat cushion 122 is formed from a plurality of strands 228 of an extruded and expanded thermoplastic resin. The seat cushion 122 is also formed with a layer or film 230 of extruded thermoplastic resin that is bonded to and integrally formed with the plurality of strands 228.

[0092] 7, seat cushions 122, 124 are produced from the system 10 and process of extruded thermoplastic resin netting. The hopper 12 holds the material inventory to be extruded, for example as solid granules or pellets of material. The material may be provided by a plastic such as linear low density polyethylene (LLDPE). The material is fed from the hopper 12 to the extruder 16.

[0093] The extruder 16 melts the material and delivers it to the die plate 20. In one non-limiting example, the extruder 16 includes a barrel that receives a rotatable screw as well as a heating element. The rotation of the screw moves the material through the barrel and helps heat the material due to the friction generated as the screw rotates. The material exits the extruder 16 in a molten state under pressure.

[0094] The die plate 20 extrudes the material into filaments 24. The die plate 20 may be provided as described below depending on the direction of extrusion relative to the final parts 122, 124 produced therefrom. More specifically, the die plate 20 has a plurality of small circular through holes or openings through which the molten material passes. A single filament 24 is extruded from each die plate hole. The filament 24 falls downward from the die plate under system pressure and gravity, as described below, into a funnel 26. The funnel 26 may have a cross-sectional shape that is the same as or different from the shape collectively defined by the openings in the die plate.

[0095] The funnel 26 helps connect or group the filaments 24 together, causing the filaments 24 to bend or loop into a more compact arrangement with each filament 24 touching and bonded to at least one other filament 24. The funnel 26 has a funnel entrance 28 and a funnel exit 30 that is smaller than the funnel entrance. The funnel 26 is narrower at the funnel exit 30 than the funnel entrance 28. Separate individual filaments 24 enter the funnel entrance 28, the filaments 24 bend / loop and move in contact with each other as they slide down the funnel 26 toward the funnel exit as they accumulate, and the connected filament structure 32 exits the funnel exit 30 and immediately enters the water tank.

[0096] The liquid tank 34 holds water 36 or other fluid and receives the connected filament structure 32 from the funnel 26. The liquid 36 in the tank 34 temporarily supports the connected filament structure 32, preventing it from collapsing or condensing into a less open or less porous arrangement and helping to maintain the desired porosity and density. As such, the liquid 36 provides some resistance to further cause bends and loops in the filaments 24, further building up the connected filament structure 32. Second, the liquid 36 externally cools the filaments 24, solidifying them and preventing them from bonding in additional locations.

[0097] The tank 34 includes various rollers and conveyors, such as a tractor conveyor 38, that aid in moving the connected filament structure 32 through and out of the liquid 36. The speed of the rollers and conveyors can be controlled to move the connected filament structure 32 away from the funnel 26 at a rate that is dependent on the rate at which the connected filament structure 32 exits the funnel 26.

[0098] Other rollers, such as roller 40, help guide the connected filament structure 32 through the liquid 36 while keeping it submerged in the liquid 36 and towards a conveyor belt 42 and shaking table 44 located outside the tank 34. The shaking table 44 shakes the connected filament structure 32 while it is on the conveyor belt 42 to remove the liquid 36. Pressurized air may additionally or alternatively be blown towards the connected filament structure 32 and / or the connected filament structure 32 may be compressed to remove the liquid 36. The connected filament structure 32 may then be cut into desired sizes and shapes.

[0099] FIG. 13 shows a top view of the extrusion die 20 according to one embodiment. The extrusion die 20 includes a plurality of openings or nozzles 238 formed therethrough for extruding the threads 228. The die 20 also includes a plurality of slits 244 formed therethrough for extruding the film 230 simultaneously with the threads 228. Each thread 228 is a strip of material having a small cross-section and easily bent, curved, or otherwise joined in various directions to form the mesh-like pattern of the cushion 122. The film 230 has a cross-section with a width sufficient to cover most or all of the cushion 22. The film 230 also has a relatively thin thickness to provide a continuous layer 230 on the cushion 122. In the illustrated embodiment, the slits 244 have parallel thicknesses to provide a flat film 230. However, any cross-sectional slit 244 can be used. The slits 244 can also have a thickness greater than the diameter of the threads 228.

[0100] FIG. 14 shows the continuous flow of molten thermoplastic resin in filaments 228 and films 230 from the extrusion die 20. Unless otherwise stated, the term "molten" as used herein means that the material is at least partially molten. This does not mean that the material is necessarily in a completely liquid state. Rather, it means that the material is not completely solid and can still flow through the elements of the system 10. For example, the molten material can still flow through the die plate 20, but it may be very viscous and begin to solidify. Solid granules of polymeric material are melted in the extruder 16, but as the material is no longer agitated by the extruder screw and moves away from the heater, it begins to cool. At different points in the process 11, the material may have a higher or lower viscosity, but the term "molten" applies here if it is still partially molten and can flow, even if slowly.

[0101] FIGURE 15 also illustrates the extrusion of the filaments 228 and film 230 from the extrusion die 20. In FIGURE 15, the molten filaments 228 and film 230 are shown entering and passing through the funnel plate 26 toward the cooling chamber 34. Within the cooling chamber 34, the flow of the filaments 228 is resisted by the fluid, causing them to bend, curve, and bond with one another, with a subset of the filaments 228 also engaging and bonding with the film 230. The filaments 228 and film 230 also cool and solidify within the cooling chamber 34, causing the filaments 228 and film 230 to be united as the cushion 122.

[0102] The film 230 may also bend or deform within the fluid chamber 34. Increasing the thickness of the film 230 relative to the threads 228 resists deformation to the film 230 and is optimized for a relatively flat film 230. As shown in Figures 12, 13, and 14, one of the films 230 is formed on the outer surface of the cushion 122. Figures 13, 14, and 15 also show that another one of the films 230 is formed within the cushion 122 and between two subsets of the threads 228.

[0103] The outer film 230 provides a continuous seating surface tension across the cushion 122, similar to a skin along the foam cushion, to support and provide comfort to the occupant. The film 230 also provides a surface for attaching other seating components by adhesive, hook and loop fasteners, etc. As shown in FIG. 12, another layer 246 is attached to the outer film 230. According to one embodiment, the layer 246 is a trim cover. According to another embodiment, the layer 246 is an actuator, such as a bladder assembly. Additionally, according to another embodiment, the layer 246 is a heat transfer layer, such as a heating mat.

[0104] The film 230 is formed impermeable over areas including the air permeable regions of the cushion 122 formed from the network of threads 228 to provide a boundary that closes the network 228 for ventilation. Openings 248 are formed through the film 230 to provide vents, ducts, plenums, etc. for transporting fluids through the cushion 122 to heat or cool the occupant. The openings 248 formed through the film 230 are a post-extrusion process such as a stamping or cutting process.

[0105] Although two parallel films 230 are shown in Figures 13-15, any amount of film 230 can be developed at any angular orientation based on the placement of slits 244 in extrusion die 20. The temperature and pressure of extruder 16 can also be varied to change the thickness or flatness of film 230.

[0106] The seat cushions 122, 124 are often molded from foam materials. Foam cushions require dedicated tooling to mold each cushion component. In contrast to the prior art molding tools, the seat cushion 122 requires a dedicated extrusion die 20. The system 10 includes a flexible apparatus suitable for manufacturing a variety of cushions using a variety of extrusion dies 20. After a quantity of the cushion 122 is manufactured, the extrusion die 20 is removed from the extruder 16. Then, another extrusion die 20 is installed with a specific pattern of openings 238 and slits 244 for another cushion 122. Then, a quantity of the second cushion 122 is extruded through the second extrusion die 20.

[0107] A method 170 is described for forming a non-foam cushion having a film (e.g., 230). The method 160 includes discharging 172 (e.g., from an extruder) molten thermoplastic resin as a plurality of filaments (e.g., 228) and at least one film (e.g., 230).

[0108] The method 170 includes providing resistance 174 (e.g., with a fluid such as water) to the flow of the extruded plurality of filaments (e.g., 228), where providing resistance includes expanding the plurality of filaments (e.g., 228) by causing at least a subset of the plurality of filaments (e.g., 228) to cross and bond with one another and become one with at least one film (e.g., 230).

[0109] In some embodiments, the method 170 includes cooling 176 the plurality of filaments (eg, 228) and at least one film (eg, 230) as a single product.

[0110] In some embodiments, the method 170 includes cooling the plurality of filaments (e.g., 228) and at least one film (e.g., 230) with a fluid, where a flow of the plurality of filaments (e.g., 228) is resisted by the fluid.

[0111] In some embodiments, the method 170 includes cooling a plurality of filaments (eg, 228) in a fluid chamber.

[0112] In some embodiments, the method 170 includes dispensing at least one film (eg, 230) onto an exterior surface of the unitary body.

[0113] In some embodiments, the method 170 includes dispensing at least one film (e.g., 230) between at least two subsets of the plurality of filaments (e.g., 228).

[0114] In some embodiments, the method 170 includes forming an opening through at least one film (eg, 230).

[0115] In some embodiments, the discharging further includes discharging a plurality of filaments (e.g., 228) through a plurality of openings in the tool and discharging at least one film (e.g., 230) through at least one slit in the tool.

[0116] In some embodiments, the method 170 includes removing the tool from the extruder, attaching a second tool to the extruder, extruding molten thermoplastic resin through the second tool as a second plurality of filaments (e.g., 228) and a second film (e.g., 230), and providing resistance to flow of the extruded second plurality of filaments (e.g., 228), the resistance including expanding the second plurality of filaments (e.g., 228) by causing at least a subset of the second plurality of filaments (e.g., 228) to cross one another and form a second film and a second unitary body different from the first unitary body.

[0117] In some embodiments, the method 170 includes assembling a seat with a cushion formed by the method.

[0118] Describing the Product: The product is formed by any of the methods of the aforementioned techniques.

[0119] The product is formed by the method 170. The method 180 includes dispensing 172 molten thermoplastic resin into a plurality of filaments (e.g., 228) and at least one film (e.g., 230).

[0120] The method 170 includes providing resistance 174 to the flow of the extruded strands (e.g., 228), where providing resistance includes expanding the strands by causing at least a subset of the strands (e.g., 228) to cross over one another and become one with at least one film (e.g., 230).

[0121] In some embodiments, the method 170 includes forming at least one film (e.g., 230) on an exterior surface of the unitary body. In some embodiments, the method 170 includes forming at least one film (e.g., 230) as an impermeable film (e.g., 230) between at least two subsets of the plurality of filaments (e.g., 228).

[0122] In some embodiments, the method 170 includes forming an opening through at least one film (eg, 230).

[0123] The seat assembly is manufactured by a method 180. The method 180 includes assembling 182 a seat with a cushion formed by the techniques described above.

[0124] In some embodiments, the method 180 includes attaching 184 at least one of the seat trim, the actuator, and / or the heat transfer layer to at least one film (eg, 230).

[0125] Describing an article of manufacture, the article of manufacture includes an expanded network of a plurality of interconnected thermoplastic filaments (e.g., 228) and at least one thermoplastic film (e.g., 230) integrally bonded to at least a subset of the plurality of filaments (e.g., 228) as a unitary entity.

[0126] In some embodiments, at least one film (eg, 230) is stretched onto the outer surface of the unitary body.

[0127] In some embodiments, at least one film (eg, 230) is impermeable.

[0128] In some embodiments, at least one film (eg, 230) is stretched between at least two subsets of the plurality of filaments (eg, 228).

[0129] In some embodiments, the opening extends through at least one film (eg, 230).

[0130] The seat assembly includes any of the above-mentioned products as a seat cushion.

[0131] In some embodiments, the seating assembly includes at least one of a seat trim, an actuator, and / or a heat transfer layer attached to at least one film (eg, 230).

[0132] A tool is described, the tool comprising a body having a plurality of openings formed therethrough and at least one slit formed therethrough, the body being configured to dispense molten thermoplastic resin through the plurality of openings and the at least one slit.

[0133] A system is described, comprising an extruder of molten thermoplastic resin and the tool of claim 65 attached to the extruder, configured to pass the molten thermoplastic resin through the tool and extrude it as a plurality of filaments (e.g., 228) and at least one film (e.g., 230).

[0134] Referring to FIG. 1, a schematic diagram of a system 10 usable in a method 11 according to embodiments described herein is shown. A hopper 12 holds solid granules of polymeric material 14 to be extruded. In this embodiment, the material 14 is linear low density polyethylene (LLDPE), however, the methods described herein can use different types of polymers as desired and effective to produce an end product. The material 14 is fed from the hopper 12 to an extruder 16. The extruder 16 melts the material 14 and delivers it to a die plate apparatus 18 including a die plate 20. The extruder 16 may be, for example, a conventional extruder including a barrel that receives a rotatable screw. The rotation of the screw moves the material 14 through the barrel and helps heat the material due to friction generated as the screw rotates. A heating element may be disposed in the barrel to heat the polymeric material 14 within the barrel.

[0135] Material 14 exits extruder 16 under pressure in a molten state at location 22. Unless otherwise stated, the term "molten" as used herein means that the material is at least partially molten. This does not mean that the material is necessarily in a completely liquid state. Rather, it means that the material is not completely solid and can still flow through the elements of system 10. For example, the molten material can still flow through die plate 20, but may be very viscous and begin to solidify. Solid granules of polymeric material 14 are melted in extruder 16, but as the material is no longer agitated by the extruder screw and moves away from the heater, it begins to cool. At different points in the process 11, the material may have a higher or lower viscosity, but still be partially molten and able to flow, even if slowly, and the term "molten" applies here.

[0136] The die plate 20 extrudes the material 14 into filaments 24. A single filament 24 is extruded from each die plate hole. The filaments 24 fall downward from the die plate 20 under system pressure and gravity into a funnel 26. The funnel 26 helps the filaments 24 to join or group together into a more compact arrangement in which the filaments 24 bend or loop and each filament 24 contacts and joins at least one other filament 24. In this embodiment, the funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. More specifically, the funnel 26 is narrower at the funnel outlet 30 than the funnel inlet 28. The separate individual filaments 24 enter the funnel inlet 28, then the filaments 24 bend or loop and move in contact with each other as they slide down the funnel 26 toward the funnel outlet 30 while being deposited, and the joined filament structure 32 exits the funnel outlet 30 into a water tank 34. When the filaments 24 reach the funnel 26, those filaments near the outer portion of the funnel 26 (approximately two to three rows) slide down the sloping surface of the funnel 26, thereby forming a skin on the connected filament structure 32.

[0137] The water tank 34 holds water 36 and receives the connected filament structure 32 from the funnel 26. The water 36 serves at least two functions. First, it temporarily supports the connected filament structure 32, helping to prevent it from collapsing or condensing into a less open or less porous arrangement. As such, the water 36 provides some resistance to further bending or looping the filaments 24, further building up the connected filament structure 32. Second, the water 36 externally cools the polymer filaments 24, causing them to solidify. The temperature of the water 36 may be much lower than the temperature of the filaments 24 when they leave the die plate 20, for example, the temperature of the ambient environment surrounding the tank 34. The fluid used in this embodiment is liquid water 36, although other types of fluids may be used in other embodiments.

[0138] The water tank 34 includes various rollers and conveyors that aid in moving the connected filament structure 32 through and out of the water 36. The tow conveyor 38 is submerged in the water 36 and engages both sides of the connected filament structure 32 to move it away from the funnel 26 at approximately the same speed as it exits the funnel 26. The gap between the opposing portions of the tow conveyor 38 is slightly narrower than the width of the connected filament structure 32 so that the tow conveyor 38 can better grip the connected filament structure 32. As previously mentioned, FIG. 1 is a schematic diagram and has been simplified for illustrative purposes. For example, conveyors such as the tow conveyor 38 may be positioned to extend from the front to the back of the system 10 in FIG. 1, rather than from side to side as shown.

[0139] Additional rollers 40 help guide the connected filament structure 32, while it remains submerged, through the water 36 toward a conveyor belt 42 and a shaking table 44 located outside the water tank 34. The shaking table 44 shakes the connected filament structure 32 while it is on the conveyor belt 42 to remove at least a portion of the water 36. Pressurized air may be blown toward the connected filament structure 32, and the connected filament structure 32 may be compressed to remove more of the water 36. Finally, the connected filament structure 32 may be cut to the desired size and shape.

[0140] FIG. 16 illustrates a die plate apparatus 46 that includes a die plate 48 and a template 50 and can be used to impart a particular shape to a final product. As discussed above in connection with FIG. 1, molten polymer is forced through openings in the die plate 48 resulting in molten polymer filaments 52 (only some of which are labeled in FIG. 17 for clarity) that form the final product after cooling. The funnel 86 also includes a template 88 that is configured similarly to the template 50 used with the die plate 48. The template 88 used with the funnel 86 helps ensure that the desired shape of the final product is maintained as the filaments 52 fall from the die plate 48 through the funnel 86.

[0141] As the filament 52 falls from the die plate 48, it begins to cool as it approaches the funnel 86. Although the filament 52 eventually cools in a fluid bath (see, for example, the water tank 34 shown in FIG. 1), it may be desirable to maintain the temperature of the filament 52 longer before it reaches the funnel 86. To achieve this result, the embodiments described herein may use a heating device 90 that surrounds the molten polymer filament 52 while it falls from the die plate 48 into the funnel 86. In the embodiment shown in FIG. 16, the heating device 90 is a rectangular heating structure that heats the filament 52 on four sides. It includes four heating plates 92, 94, 96, 98 that heat the entire periphery of the molten polymer filament 52. The heating plates 92, 94, 96, 98 surround the filament 52 as it falls from the die plate 48, although FIG. 16 shows that they have gaps between them at the four corners. In practice, a heating device such as the heating device 90 may surround the filament without having any space or gaps around the associated filament.

[0142] The embodiments described herein contemplate the use of different types of heating devices, including different geometric configurations, distances from the associated filaments, and amounts of heat generated. For example, in some embodiments, a heating device, such as heating device 90, can use radiant heat as the sole or primary source of heat control. In other embodiments, convection heaters, or a combination of convection and radiant heaters, can be used. In the embodiment shown in FIG. 16, the heating plates 92, 94, 96, 98 are positioned between 100 millimeters (mm) and 150 mm from the outermost filament 52. Thus, the heating device 90 is located at least 100 mm to 150 mm from any of the filaments 52. The heating device 90 can operate to control the ambient temperature around the molten polymer filaments 52 to a temperature between 60° C. and 140° C., although other embodiments can use temperatures outside this range depending on the application and the desired properties of the end product. In the embodiment shown in FIG. 16, the heating apparatus 90, specifically the heating plates 92, 94, 96, 98, are attached directly to the die plate 48, although in other embodiments the heating apparatus may be self-supporting or may be attached to a structure other than the associated die plate.

[0143] Heating a molten polymer filament, such as filament 52, as it leaves the die plate and before it reaches the associated funnel can have many advantages. For example, heating device 90 can be configured to heat an outer portion of filament 52 and can operate to maintain a constant temperature around the outside of filament 52, resulting in a uniform bond between filaments 52. In the absence of a heating device, such as heating device 90, ambient conditions can affect filaments 52 falling into funnel 26 differently than others. This can lead to inconsistent bonds between filaments 52 on different parts of the final product. In contrast, by heating the entire periphery of molten polymer filament 52, bonds can be maintained consistently. Additionally, applying heat as filament 52 falls from die plate 48 can create stronger bonds between filaments by keeping filament 52 at its melting temperature longer or melting it to a more liquid state as it travels downward. This can provide a stronger or tougher outer portion of the final product, i.e., forming a kind of "shell," which is desirable in some applications.

[0144] Another advantage of using a heating device such as heating device 90 is that it can work in conjunction with a second or "co-extruded" material being added to the process 11 shown in FIG. 1. Shown in hidden lines in FIG. 1 is another extruder 68 configured to receive polymeric material 70 from a hopper 72. The polymeric material 70 is different from the polymeric material 14 fed from the hopper 12 to the extruder 16. Similar to the extruder 16, the extruder 68 heats the material 70 to a molten state and moves it to the die plate apparatus 18. The material 70 can be conveniently referred to as a first material, and once heated, can be referred to as a first molten polymer 70. Similarly, the material 14 can be conveniently referred to as a second material, and once heated, can be referred to as a second molten polymer. As shown in FIG. 1, the extruder 68 is positioned to feed the first molten polymer 70 toward the outer edge of the die plate 20, where it forms a plurality of first molten polymer filaments that at least partially surround the second polymer filaments 24.

[0145] The relationship between the inner and outer polymer filaments created in the coextrusion system is shown in FIG. 16. Specifically, the molten polymer filaments 52 are made from a first molten polymer and are located near the outer edge of the die plate 48. In contrast, a second group of molten polymer filaments 74 (only some of which are labeled in FIG. 16 for clarity) are made from a second molten polymer and are located inward from the first molten polymer. With this configuration, the first molten polymer filaments 52 at least partially surround the second molten polymer filaments 74. As mentioned above, FIG. 16 is a schematic of the actual process, with some elements removed for clarity. In reality, the area below the die plate 48 leading to the funnel 26 will be crowded with many more first and second molten polymer filaments 52, 74 than are shown.

[0146] Regardless of whether a single material or multiple materials are used in the coextrusion process, the embodiments described herein provide advantages based on the use of a heating device to control the temperature of the molten polymer filament exiting the die plate. FIG. 17 shows a single molten polymer filament 76 immediately after exiting the die plate. More specifically, the top 79 of the molten polymer filament 76 is located just below the die plate that extrudes it, while the bottom 80 of the filament 76 is located near the entrance to a funnel shown in FIG. 17, such as funnel 26. Without the use of a heating device shown in FIG. 17, such as heating device 90, the top 79 of the filament 76 would be much hotter than the bottom 80. There would be a temperature gradient between the top 79 and bottom 80, which may or may not be uniform depending on the ambient conditions surrounding the filament 76. However, in the embodiment shown in FIG. 17, a heating device 83 is placed around the filament 76 to control the ambient temperature and ultimately the temperature of the filament 76 itself.

[0147] While FIG. 17 shows heating device 83 on only two sides of filament 76, it is understood that heating device 83 may be configured to surround the filament, and indeed all filaments exiting the die plate, as shown in FIG. 16. As discussed above, controlling the temperature of the molten polymer filament as it leaves the die plate can provide desirable characteristics in the final product. FIG. 18 shows a cross section of a connected filament structure 84 made in accordance with an embodiment of the systems and methods described herein. As shown in FIG. 18, connected filament structure 84 includes an outer portion 87 disposed about the circumference and an inner portion 85 disposed inwardly from outer portion 87.

[0148] As shown in FIG. 18, the outer portion 87 is different from the inner portion 85. For example, the outer portion 87 can have better bonding between the individual filaments through the use of a heating device, such as the heating device 90 shown in FIG. 17. As a result, it may be denser. Alternatively, the outer portion 87 can include a first group of molten polymer filaments made from a first material, while the inner portion 85 can include a second group of molten polymer filaments made from a second material different from the first material. In at least some embodiments, two different materials can be used with the heating device to provide a final product having a first material around the outside of the product. This first material is more tightly bonded and denser than the second material disposed inward from the first material. Thus, the embodiments described herein provide systems and methods with the flexibility to control the properties of the final product through the use of different materials and heat control.

[0149] Disclosed is a method 190 for manufacturing a vehicle interior part. The method 190 includes heating 191 a polymeric material (e.g., 14 and / or 70) to a molten state such that it becomes a molten polymer.

[0150] The method 190 includes introducing molten polymer into a die plate (e.g., 48) having a plurality of holes disposed therethrough and forcing the molten polymer through the holes to form 192 a plurality of molten polymer filaments.

[0151] The method 190 includes surrounding 193 the molten polymer filament with a heating device (e.g., 92-98) operable to apply heat to the molten polymer filament.

[0152] The method 190 includes introducing 186 molten polymer filaments into the bath and cooling the molten polymer filaments to form an interconnected filament structure.

[0153] In some embodiments, the heating devices (e.g., 92-98) include rectangular heating structures that surround the molten polymer filaments as they leave the die plate (e.g., 48).

[0154] In some embodiments, the die plate (eg, 48) includes multiple sides and a heating device is attached to each side of the die plate (eg, 48).

[0155] In some embodiments, the heating device is configured to control the ambient temperature around the molten polymer filaments to a temperature between 60°C and 140°C.

[0156] In some embodiments, the heating device is located at least 100 mm to 150 mm from the molten polymer filaments.

[0157] In some embodiments, the molten polymer filaments include an outer portion (e.g., 87) disposed on a side of an outer edge of the die plate (e.g., 48) and an inner portion (e.g., 85) disposed inward from the outer portion (e.g., 87), and the heating device is configured to heat the outer portion (e.g., 87) such that bonds between the molten polymer filaments in the outer portion (e.g., 87) are greater than bonds between the molten polymer filaments in the inner portion (e.g., 85).

[0158] In some embodiments, the molten polymer is a first molten polymer including a first material, the molten polymer filament is a first molten polymer filament, and the method further includes introducing a second molten polymer including a second material into the die plate (e.g., 48), where the second molten polymer travels through holes in the die plate (e.g., 48) to form a plurality of second molten polymer filaments.

[0159] In some embodiments, a first molten polymer is introduced into the die plate (e.g., 48) on an outer edge side of the die plate (e.g., 48) and a second molten polymer is introduced into the die plate (e.g., 48) inwardly from the first molten polymer, such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0160] A vehicle interior part may be formed by any of the techniques described above.

[0161] Disclosed is a method 194 for manufacturing a vehicle interior part. The method 194 includes heating 195 a first polymeric material to a molten state to produce a first molten polymer.

[0162] The method 194 includes extruding a first molten polymer to form a plurality of first molten polymer filaments 196. The method 194 includes heating an entire periphery of the first molten polymer filaments 197. The method 194 includes cooling the first molten polymer filaments in a fluid bath 198 to form a connected filament structure.

[0163] In some embodiments, the first molten polymer comprises a first material and the method further comprises extruding a second molten polymer comprising a second material to form a plurality of second molten polymer filaments.

[0164] In some embodiments, a first molten polymer and a second molten polymer are extruded such that the first molten polymer filament at least partially surrounds the second molten polymer filament.

[0165] In some embodiments, heating an entire periphery of the first molten polymer filament includes heating the first molten polymer filament on four sides of the first molten polymer filament.

[0166] In some embodiments, heating the entire periphery of the first molten polymer filament includes heating the first molten polymer filament to a temperature between 60°C and 140°C.

[0167] In some embodiments, the entire periphery of the first molten polymer filaments is heated such that there are more bonds between the first molten polymer filaments than there are bonds between the second molten polymer filaments.

[0168] A vehicle interior part may be formed by any of the techniques described above.

[0169] The method 200 manufactures a vehicle interior part. The method 200 includes heating 202 a polymeric material to produce a molten polymer. The method 200 includes forming 204 a plurality of molten polymer filaments from the molten polymer by extruding the molten polymer through a die plate (e.g., 48). The method 200 includes heating 206 an entire periphery of the molten polymer filaments with a heating device. The method 200 includes cooling 208 the molten polymer filaments in a fluid bath to form a connected filament structure.

[0170] In some embodiments, the heating device is attached to the die plate (eg, 48).

[0171] In some embodiments, the molten polymer is a first molten polymer including a first material, the molten polymer filaments are first molten polymer filaments, and the method further includes introducing a second molten polymer including a second material into the die plate (e.g., 48), the second molten polymer traveling through the die plate (e.g., 48) to form a plurality of second molten polymer filaments.

[0172] In some embodiments, a first molten polymer is introduced into the die plate (e.g., 48) on an outer edge side of the die plate (e.g., 48) and a second molten polymer is introduced into the die plate (e.g., 48) inward from the first molten polymer, whereby the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0173] 19, a seat assembly 320, such as a vehicle seat assembly 320, is shown. In other examples, the seat assembly 320 can be shaped and sized as a front row driver or passenger seat, a second, third or other rear row seat, and can include a bench style seat as shown, a bucket seat, or other seating styles. Additionally, the seat assembly 320 can be a non-stowable seat or a stowable seat that is foldable and stowable within a cavity within the vehicle floor. Additionally, the seat assembly 320 may be configured for use in other non-vehicle applications.

[0174] The seat assembly 320 optionally includes a frame 322 or other support structure. The seat assembly 320 includes seat components including at least a seat bottom 324 and a seat back 326. The seat bottom 324 may be dimensioned to receive a seated occupant and support the occupant's pelvis and thighs. The seat back 326 may be dimensioned to extend upright from the seat bottom 324 to support the occupant's back. The seat assembly 320 may further include a head rest 327. The head rest 327 is shown only for the adjacent seat assembly. The seat bottom 324 includes a seat bottom cushion 328. The seat back 326 includes a seat back cushion 330. The frame 322 may include a wire suspension mat or other structure to support the cushions 328, 330.

[0175] The frame 322 provides rigid structural support for the seat components, e.g., seat bottom 324 and seat back 326, and may be provided as multiple frame members that are movable relative to one another to provide adjustment of the seat assembly. The frame may be formed from stamped steel alloy, fiber reinforced polymer, or any suitable structural material. The frame 322 may further include a substrate, e.g., a panel, that supports an associated cushion.

[0176] One or more trim covers 332 are used to cover the seat bottom cushion 328 and the seat back cushion 330 and provide a seating surface for the seat assembly 320. The vehicle seat assembly 320 is shown without the trim covers, while the adjacent seat assembly is shown with the trim cover 332. In one example, the trim cover 332 covers both cushions 328, 330. In other examples, multiple trim covers are provided to cover the seat bottom and seat back cushions. The trim cover 332 may be formed from one or more panels of fabric, leather, synthetic leather, vinyl, or other material.

[0177] The seat cushion 340 is described in more detail below, which description may be equally applicable to the seat bottom cushion 328 or the seat back cushion 330 .

[0178] In the illustrated example, the seat cushion 340 includes at least one non-foam part or member 342. In one illustrated example, the seat cushion 340 is formed only from the non-foam part 342, which provides all of the cushioning for the seat component between the frame 322 and the trim cover 332. In other examples, the seat cushion 340 can be formed from the non-foam part 342 and one or more foam or other non-foam parts, such as a part formed from molded polyurethane foam. The seat cushion 340 may have non-foam and foam parts positioned to provide different areas of the cushion 340 for the seat component. Alternatively or additionally, the seat cushion 340 can have a thin foam or other material layer disposed between the non-foam part 342 and the trim cover 332 to provide additional cushioning for one or more areas of the seat component. Additionally, the seat assembly 320 can have a heating pad or heating mat disposed between the cushion 340 and the trim cover 332. By removing some or all of the traditional foam from the seat cushion 340, the seat assembly 320 can provide improved support and comfort and can reduce weight.

[0179] FIG. 20 illustrates a cross section of a non-foam part 342 according to one embodiment of the present disclosure. Advantageously, the non-foam part 342 is a seat back or seat bottom for a vehicle. The non-foam part 342 includes a plastic mesh base 360. The plastic mesh base 360 ​​includes a first molded plurality of three-dimensional filament annulus 362 made of a first thermoplastic polymer. In this regard, the first molded plurality of three-dimensional filament annulus 362 may have a general block shape or any shape suitable for functioning as a cushion. The plastic mesh base 360 ​​has a first edge 364, a second edge 366, a first surface 368, and a second surface 370. A first bolster 374 is attached to the plastic mesh base at the first edge 364. A second bolster 376 is attached to the plastic mesh base 360 ​​at the second edge 366. The annuli are adhered to one another.

[0180] In at least one embodiment, the first bolster 374 includes a second shaped body 390 of a plurality of three-dimensional filamentary loops made of a thermoplastic polymer. In this regard, the second shaped body 390 of a plurality of three-dimensional filamentary loops has a general bolster shape or any shape suitable to function as a side bolster. In at least one embodiment, the second bolster 376 includes a third shaped body 392 of a three-dimensional filamentary loop made of a thermoplastic polymer. In this regard, the third shaped body 392 of a three-dimensional filamentary loop has a general bolster shape or any shape suitable to function as a side bolster. In at least one embodiment, the first and second bolsters 374 and 376 have the same shape. In at least one embodiment, as best shown in FIG. 19, the third (front) bolster 344 can be provided on the front of the non-foam member 342.

[0181] In one non-limiting embodiment, the non-foam component or member 342 of the seat cushion 340 is formed by at least two different threaded mesh materials, also known as entangled three-dimensional filament structures. The threaded mesh material is made of a polymer mesh having a plurality of connected polymer threads. The threaded mesh material can be made, for example, from two or more linear low density polyethylene (LLPDE) materials, although other polymers and materials are contemplated as being effective in providing the desired properties and functionality. In one non-limiting embodiment, the threaded mesh material can be formed using two or more extruded filaments of linear low density polyethylene (LLDPE) that are randomly entangled, bent, looped, or otherwise arranged and oriented and directly bonded to each other to provide a porous mesh structure, an example of which is shown in the enlarged view of FIG. 20.

[0182] In at least one embodiment, as shown, for example, in FIG. 20, the second shaped plurality of three-dimensional filamentary loops 390 are comprised of a second thermoplastic polymer different from the first thermoplastic polymer. In at least one embodiment, the third shaped plurality of three-dimensional filamentary loops 392 are comprised of a second thermoplastic polymer. In yet another embodiment, the third shaped plurality of three-dimensional filamentary loops 392 are comprised of a third thermoplastic polymer different from the first and second thermoplastic polymers. In yet another embodiment, the optional third bolster 344 is comprised of a shaped plurality of three-dimensional filamentary loops comprised of either the first, second, or third thermoplastic polymers or a fourth thermoplastic polymer different from the first, second, and third thermoplastic polymers.

[0183] For example, with reference to FIG. 20, at least a subset of the annuli within the plurality of three-dimensional filament annuli are not parallel or aligned with one another. In a refined embodiment, the annuli within the plurality of three-dimensional filament annuli are randomly oriented. The plastic netting base is 60 to 95% air by volume. In a refined embodiment, the plastic netting base is approximately (1.5 to 3.5 lbs / ft 3 That is, 24 to 56 kg / m 3) in some refinements. In some refinements, the three-dimensional filament loops include a plurality of fusion or adhesive bonds 378 where two loops are attached to each other. In some refinements, the three-dimensional filament loops are extruded thermoplastic polymers. Examples of thermoplastic polymers include, but are not limited to, polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In some refinements, the thermoplastic polymer includes linear low density polyethylene. In some refinements, the three-dimensional filament loops have a fineness of 200 to 10,000 decitex. In some refinements, the three-dimensional filament loops have a fineness of 200 to 5,000 decitex. In further refinements, the three-dimensional filament loops have a fineness of 200 to 3,000 decitex.

[0184] In at least one embodiment, the first, second, third and / or fourth thermoplastic polymers can be, independently, any suitable thermoplastic elastomer (TPE), such as LLDPE, thermoplastic polyetherester elastomer (TPEE), thermoplastic polyurethane (TPU), styrenic thermoplastic elastomer (TPS) or thermoplastic vulcanizate (TPV). In at least one embodiment, the first, second, third and / or fourth thermoplastic polymers can be varied independently from one or more of the others to provide variable density at various locations of the non-foam component 342. For example, the first and / or second bolsters 374, 376 can have a higher density than the mesh base 360.

[0185] In at least one embodiment, the first thermoplastic polymer comprising the first shaped plurality of three-dimensional filamentary annulus 362 is comprised of LLDPE (Linear Low Density Polyethylene) having a first density, and one or more of the second, third and fourth thermoplastic polymers comprising the second shaped plurality of three-dimensional filamentary annulus 390, the third shaped plurality of three-dimensional filamentary annulus 392 and the shaped plurality of three-dimensional filamentary annulus comprising the first bolsters 374, 376 and 344, respectively, are comprised of LLDPE (Linear Low Density Polyethylene) having a second density greater than the first density. Additionally or alternatively, to vary density, the first shaped plurality of three-dimensional filamentary annulus 362 is comprised of a first material having a first property, and one or more of the second, third and fourth thermoplastic polymers comprising the second shaped plurality of three-dimensional filamentary annulus 390 are comprised of a second material having a property different from the first property. In addition to density, examples of other different properties can include different (eg, higher or lower) bond quality or heat resistance.

[0186] Methods are provided that can be used to form member 342, assemble cushion 340, and assemble seat assembly 320. In various examples, the methods may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0187] 1 illustrates a method and manufacturing process 10 for forming threaded braided material members, such as member 342 for cushion 340, for use in the present method according to embodiments. The method may be used to form members for cushions, such as member 342 described above, and may also be used to assemble seats, such as seat assembly 320. In various examples, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0188] 1, an interconnected filament structure 32 is formed which may provide a threaded braided material that forms the cushion 340 and member 342 as described above.

[0189] 1, a first hopper 12 holds a first stock of material to be extruded, for example as solid granules or pellets of material. The first material may be provided by a plastic such as Linear Low Density Polyethylene (LLDPE). The first material is fed from the first hopper 12 to a first extruder 16.

[0190] A second hopper 72 is also provided that holds a second stock of material to be extruded, for example as solid granules or pellets of material. The second material may be provided by a plastic such as Linear Low Density Polyethylene (LLDPE) that is a different grade than the LLDPE of the first material. For example, the second material may be a different grade (Grade 1, Grade 2, etc.) or a different type (TPEE, TPV, etc.). The second material is fed from the second hopper 72 to the second extruder 68.

[0191] The first extruder 16 and the second extruder 72 melt the first material 14 and the second material 70, respectively, and convey the melted first material 14 and the second material 70, respectively, to the die plate 20. The melted first material and the second material do not mix with each other. Thus, the first extruder 16 and the second extruder 72 co-extrude the first material and the second material, respectively, to the die plate 130. In one non-limiting example, the extruders 16 and 72 include barrels that receive rotatable screws and heating elements. The rotation of the screws moves the first material 14 and the second material 70 through the respective barrels and helps heat the first material 14 and the second material 70 due to friction generated when the screws rotate. The first material 14 and the second material 70 exit the extruders 16 and 72 in a molten state under pressure.

[0192] The die plate 20 extrudes the first and second materials into filaments 24. More specifically, the filaments include a first plurality of filaments 24', a second plurality of filaments 24", and an optional third plurality of filaments 24'" of the first material. In at least one embodiment, one or both of the second plurality of filaments 24" and the third plurality of filaments 24"' are comprised of the second material. Alternatively, one of the second plurality of filaments 24" and the third plurality of filaments 24"' may be comprised of the first material. Additionally, in at least one embodiment, the first plurality of filaments 24', the second plurality of filaments 24", and the third plurality of filaments 24"' may all be comprised of different materials, either in material type and / or grade.

[0193] The die plate 20 can be provided as described below depending on the direction of extrusion for the final part 342 produced therefrom. More specifically, the die plate 20 has a number of small circular through holes or openings 351 through which the molten material passes, as shown in FIG. 21. A single filament 380, 384, 386, 388 is extruded from each hole in the die plate. The die plate 20 has a central portion 351 and two side portions 355 on either side of the central portion 351. A first material is extruded from the central portion 351 to form a filament 384 that forms the plastic netting base 360, and one or both of the two side portions 355 extrude a material different from the first material, such as a second material and possibly a third material, to form a first bolster 374 and a second bolster 376. The filament 140 falls downward from the die plate into the funnel 26 under pressure and gravity, as described below. The funnels 26 may have a cross-sectional shape that is the same as or different from the shape collectively defined by the openings in the die plate.

[0194] The funnel 26 helps connect or group the filaments 380 together, causing the filaments 380 to bend or loop into a more compact arrangement with each filament 380 touching and bonded to at least one other filament 380. The funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. The funnel 26 is narrower at the funnel outlet 30 than the funnel inlet 28. Separate individual filaments 380 enter the funnel inlet 28, then the filaments 380 bend / loop and move in contact with each other as they slide down the slope of the funnel 26 toward the funnel outlet 30 while depositing, forming a material skin with two or three rows of filaments, and the connected filament structure 32 exits the funnel outlet 30 and immediately enters the water tank 34.

[0195] The liquid tank 34 holds water 36 or another fluid and receives the connected filament structure 32 from the funnel 26. The liquid 36 in the tank 34 temporarily supports the connected filament structure 32, preventing the filament structure from collapsing or condensing into a less open or less porous arrangement and helping to maintain the desired porosity and density. As such, the liquid 36 provides some resistance to further cause the filaments 380 to bend and loop, further building up the connected filament structure 32. Second, the liquid 36 cools the filaments 380 from the outside, solidifying the filaments 380 and preventing them from bonding in additional locations.

[0196] The tank 34 contains various rollers and conveyors, such as a tractor conveyor 38, that help move the connected filament structure 32 through and out of the liquid 36. The speed of the rollers and conveyors may be controlled to move the connected filament structure 32 away from the funnel 26 at a rate that is dependent on the speed at which the connected filament structure 32 exits the funnel 26.

[0197] Other rollers, such as roller 40, help guide the connected filament structure 32 through the liquid 36 while keeping it submerged in the liquid 36 to a conveyor belt 42 and a shaking table 44 located outside the tank 34. The shaking table 44 shakes the connected filament structure 32 while it is on the conveyor belt 42 to remove the liquid 36. Pressurized air may also or alternatively be blown towards the connected filament structure 32 and / or the connected filament structure 32 may be compressed to remove the liquid 36. It should be noted that parts 12, 72, 16, 20 and 26 are shown in a front view in FIG. 1, while parts 34, 38, 40, 42 and 44 and the funnel are shown in a side view for better understanding.

[0198] In one example, the connected filament structure 32 may be generally formed with two or more surfaces for the members 342 based on the shape of the die 20 and funnel 26. In other examples, the connected filament structure 32 may require further processing, as described below, to give the members 342 a desired shape.

[0199] The interlocking filament structure 32 is then cut to a desired size and shape to form the perimeter or entire or contour of the member 342. After forming the member 342, the seat assembly 320 can be assembled. The member 342 is attached to a frame 322 of the seat assembly to provide the cushion 340. A trim cover 332 may be placed over the member 342 and the cushion 340. The trim cover 332 may be connected to the cushion 340 and / or the frame 322. In one example, the trim cover 332 may be connected by tie-downs or other fasteners.

[0200] In a variation, the three-dimensional filament loop and optional skin layer are constructed from a thermoplastic polymer.

[0201] A vehicle seat cushion component is described, the vehicle seat cushion component includes a plastic mesh base (e.g., 360), the plastic mesh base (e.g., 360) includes a first plurality of three-dimensional filament annuli, the first plurality of three-dimensional filament annuli comprised of a first thermoplastic polymer, the plastic mesh base (e.g., 360) having a first side edge, a second side edge, a leading edge, a trailing edge, a first face, and a second face.

[0202] The vehicle seat cushion component includes a first bolster attached at a first edge to a plastic mesh base (e.g., 360), the first foam bolster including a second plurality of three-dimensional filament annuli, the second plurality of three-dimensional filament annuli comprised of a second thermoplastic polymer different than the first thermoplastic polymer. The vehicle seat cushion component includes a second bolster attached at a second edge to the plastic mesh base (e.g., 360).

[0203] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being composed of a second thermoplastic polymer.

[0204] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

[0205] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being made of a third thermoplastic polymer different from the first and second thermoplastic polymers.

[0206] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

[0207] In some embodiments, the vehicle seat cushion component further includes a third bolster including a fourth plurality of three-dimensional filament annuli, the fourth plurality of three-dimensional filament annuli being comprised of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0208] In some embodiments, the multiple three-dimensional filament loops include multiple fusion connections where two loops are attached to one another.

[0209] In some embodiments, at least a subset of the rings within the plurality of three-dimensional filament rings are not parallel or aligned with one another.

[0210] In some embodiments, the loops within the multiple three-dimensional filament loops are randomly oriented.

[0211] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0212] In some embodiments, the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0213] In some embodiments, the thermoplastic polymer comprises a first linear low density polyethylene.

[0214] In some embodiments, the thermoplastic polymer comprises a second linear low density polyethylene that is different from the first linear low density polyethylene.

[0215] A seat assembly is described below: The seat assembly includes a frame and a cushion according to any of the above techniques, the cushion being supported by the frame.

[0216] A tool is described, the tool including a die defining a series of openings configured to extrude material for the threaded mesh material member for a cushion according to any one of claims 87 to 99, the series of openings being arranged to define the periphery of the members defining the plastic mesh base (e.g. 360), the first bolster and the second bolster.

[0217] In some embodiments, the series of openings are further arranged such that the perimeter defines a bolster.

[0218] 2 illustrates a method 210 including extruding 212 a first thermoplastic polymer to form a plastic braided base (e.g., 360) including a first plurality of three-dimensional filament annuli, the plastic braided base (e.g., 360) having a first side edge, a second side edge, a leading edge, a trailing edge, a first face, and a second face, the method including extruding 214 a second thermoplastic polymer to form a first bolster attached to the plastic braided base (e.g., 360) at the first edge, the first foam bolster including a second plurality of three-dimensional filament annuli, the second thermoplastic polymer being different from the first thermoplastic polymer.

[0219] The method 210 includes extruding 216 the material to form a second bolster attached at a second edge to a plastic mesh base (eg, 360).

[0220] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a second thermoplastic polymer.

[0221] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being composed of a third thermoplastic polymer different from the first thermoplastic polymer.

[0222] In some embodiments, the second bolster includes a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being composed of a third thermoplastic polymer different from the first and second thermoplastic polymers.

[0223] In some embodiments, the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being composed of a third thermoplastic polymer different from the first thermoplastic polymer.

[0224] In some embodiments, the present technology includes a third bolster comprising a fourth plurality of three-dimensional filament loops, the fourth plurality of three-dimensional filament loops being composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0225] Referring to Fig. 22, a seat assembly 400 is disclosed. In one embodiment, the seat assembly 400 includes a seat frame 402, one or more seat cushions 404, and a trim cover 406. In modified embodiments, the seat assembly 400 may include additional components such as, but not limited to, a massage assembly, a ventilation assembly, a heating assembly, and / or a sensor assembly. In modified embodiments, the seat assembly 400 is a seat for a vehicle, such as an automobile, a motorcycle, an aircraft, a watercraft, and / or a train.

[0226] In one embodiment, the one or more cushions 404 include a seat bottom and / or a seat back. Unlike conventional seat cushions, which are generally injection molded foams, the seat cushion of the seat assembly 400 may be a non-foamed, non-foamed, non-foamed and / or non-woven mesh cushion 408 of intertwined and / or entangled polymer strands 410, as shown in FIG. 23. The various polymer strand portions are entangled with other polymer strand portions such that the multiple polymer strands function as a single unit, piece, cushion, pillow, pad or mat. Hereinafter, this disclosure refers to it as a non-foamed cushion 408 or a non-foamed cushion 408. The polymer strands are any suitable polymeric material, such as a thermoplastic polymer (e.g., polyolefin, polyethylene, polypropylene, polystyrene, polycarbonate, polyurethane and / or polyvinyl chloride).

[0227] In a modified embodiment, the non-foam cushion 412 includes a first portion / section / region / volume / zone 414 having a first hardness and a second portion / section / region / volume / zone 416 having a second hardness different from the first hardness, as shown in FIG. 23. In a modified embodiment, the hardness is determined for equivalent volumes according to ASTM 3574. The first portion can include a first group of entangled / tangled polymeric threads and the second portion can include a second group of entangled / tangled polymeric threads. Hereinafter, in this description, the portions of the cushion are referred to as portions of the cushion, but may equally be referred to as sections, regions, volumes, zones and / or groups of polymeric threads. It should also be understood that, although differently referenced, the portions are connected by entangled or tangled polymeric threads.

[0228] In one variation, the first portion 414 is stiffer than the second portion 416. In another variation, the second portion 416 is stiffer than the first portion 414. For example, the first portion 414 is stiffer than the second portion 416, which may be a bolster area of ​​a seat bottom, or may be a seat portion.

[0229] The non-foam cushion 412 includes other portions having different hardnesses. For example, the cushion 412 includes a third portion 418 having a third hardness that is different from the second hardness. In a refined embodiment, the third hardness is the same or substantially the same as the first hardness (i.e., within manufacturing tolerances, within 1%, 1.5%, 3%, 5%, or 10%).

[0230] In one or more embodiments, the first and second hardnesses may differ by at least 0.5 kPa, more preferably at least 2 kPa, and even more preferably at least 4 kPa. In a refinement, one portion has a hardness of at least 5 kPa, more preferably at least 7.5 kPa, and even more preferably at least 10 kPa, and the other portion has a hardness of 5 kPa or less, more preferably 4.5 kPa or less, and even more preferably 4.0 kPa or less.

[0231] In a refinement, the hardness of one portion may be from 5 kPa to 15 kPa, more preferably from 7 kPa to 12 kPa, more preferably from 8 kPa to 10 kPa, and the hardness of the other portion may be from 1 kPa to 5 kPa, more preferably from 2 kPa to 4.5 kPa, more preferably from 3 kPa to 4 kPa.

[0232] Additionally, in another variation, the non-foam cushion 412 has a firmness gradient, as shown by the shading in Figure 25. The non-foam cushion 412 has a first portion 414 having the lowest firmness (e.g., the least shaded portion), a second portion 416 having an intermediate firmness (i.e., a firmness between the first portion 414 and the third portion 416), and a third portion 418 having the highest firmness (e.g., the darkest shaded portion). The portions in between may continuously increase in firmness as one moves away from the first portion 414 and closer to the third portion 416, such that a firmness gradient exists.

[0233] In one embodiment, the first portion 414 is located at the first end 420 and the third portion 418 is located at the second end 416. In a modified embodiment, the second portion 416 may be centrally located. Alternatively, the harder or softer portion may be centrally located and the other of the harder or softer portion may be peripherally located.

[0234] In an alternative embodiment, the first portion 414 may form the top of the seat bottom so as to be positioned proximate to the occupant, and the third portion 418 may be positioned distal to the occupant, which may provide an immediate sensation of softness and / or comfort to the occupant without sacrificing long term durability and comfort.

[0235] Different portions of the non-foam cushion may provide different firmness by having different attributes or properties. For example, the bulk density of different portions may be different. In a refined embodiment, the bulk density is determined according to ISO 845. Any portion described above as having a greater firmness may also have a greater density. For example, the bolster region as shown in FIG. 24 may have a greater density than the central region. In a refined embodiment, the bulk density is at least 3.0 kg / m 3 , more preferably at least 7.0 kg / m 3 , more preferably at least 10 kg / m 3 In a variant, the difference in bulk density is between 3 and 20 kg / m 3 , more preferably 5 to 15 kg / m 3 , more preferably 6 to 12 kg / m 3 For example, a portion may have a bulk density of 60 kg / m 3 Less than or equal to 55 kg / m 3 More preferably, 50 kg / m 3 Bulk density of at least 30 kg / m 3 , more preferably 35 kg / m 3 , more preferably 40 kg / m 3 For example, one part may have a thickness of 60 to 30 kg / m3 , more preferably 55 to 35 kg / m 3 , more preferably from 50 to 40 kg / m 3 and another part has a density of ±3.0 kg / m 3 , more preferably at least 7.0 kg / m 3 , more preferably at least 10 kg / m 3 For example, another part may have a density of 57 kg / m 3 Less than or equal to 53 kg / m 3 More preferably, 50 kg / m or less 3 In yet another embodiment, the other portion has a density of at least 33 kg / m 3 , more preferably at least 37 kg / m 3 , more preferably at least 40 kg / m 3 For example, a portion may have a density of 60 to 33 kg / m 3 , more preferably from 60 to 37 kg / m 3 , more preferably 60 to 40 kg / m 3 and another part having a bulk density of 57 to 30 kg / m 3 , more preferably 53 to 30 kg / m 3 , more preferably from 50 to 30 kg / m 3 may be also possible.

[0236] In yet another embodiment, each portion has an average filament diameter. The average diameter of the first portion is different from the average diameter of the second portion. The difference may be at least 0.2 mm, more preferably at least 0.4 mm, and even more preferably 0.6 mm. The difference may be 0.1 mm to 3 mm, more preferably 0.3 mm to 1.8 mm, and even more preferably 0.5 mm to 1.2 mm. In an improved embodiment, the average diameter of one portion may be at least 1.1 times the average diameter of another portion, more preferably at least 1.5 times, and even more preferably at least 2 times the average diameter of another portion. In other words, the average diameter of one portion may be 110%, more preferably 150%, and even more preferably 200% of the average diameter of another portion. For example, in one embodiment, the average diameter of one portion is at least 1.2 mm, more preferably at least 1.4 mm, and even more preferably at least 1.6 mm, and the average diameter of another portion is 1.2 mm or less, more preferably 1.0 mm or less, and even more preferably 0.8 mm or less. In a refinement, the average diameter of one portion is from 0.05 to 10 mm, more preferably from 0.1 to 5 mm, even more preferably from 0.5 to 1.2 mm, and the average diameter of another portion is from 0.8 to 15 mm, more preferably from 1.2 to 13 mm, even more preferably from 1.6 to 10 mm.

[0237] In yet another embodiment, as shown in Figures 24-25, the third portion 303 has a different bulk density and / or average diameter than the first portion and / or the second portion. In modified embodiments, the bulk density and / or average diameter may be the same or substantially the same (i.e., within manufacturing tolerances, within 1%, 1.5%, 3%, 5% or 10%) as the first portion. In some embodiments, the second portion may be disposed between the first portion and the third portion. In other embodiments, the first portion may have the lowest bulk density and / or average diameter while the third portion may have the highest bulk density and / or average diameter (i.e., the third portion may be larger than the second portion, which may be larger than the first portion), or vice versa.

[0238] In another embodiment, the first, second and / or third portions may have threads of different shapes, such as circles, squares, triangles, stars, or various other shapes. If the shape is not circular, the diameter may be referred to as the maximum diameter of the transverse (as opposed to longitudinal) cross section of the threads to distinguish the relative dimensions of the various threads. For example, in one embodiment, a first group of threads may be circular and a second group of threads may be polygonal (e.g., rectangular).

[0239] The seat frame 402 may be made of a rigid material such as metal, plastic, wood, or a combination thereof. The seat frame 402 may support a non-foam cushion 404, other seat assemblies (e.g., massage assemblies, ventilation assemblies, electronic assemblies, etc.), and / or an occupant. For example, an aluminum seat frame 402 may be used.

[0240] In one or more embodiments, the trim cover 406 is disposed over one or more of the cushions 404 and / or the seat frame 402. The trim cover 406 is positioned to contact an occupant. For example, the trim cover 406 may be made of leather, synthetic leather, polyurethane, and / or polyester.

[0241] Referring to Figure 26, a die 500, such as a breaker plate, can be used to extrude the polymer resin as polymer filaments. In a modified embodiment, the die 500 is an interchangeable component of an extrusion system 600, as shown in Figure 27, and different dies can be used to provide cushions with different characteristics and attributes (e.g., shape, hardness, bulk density, average filament diameter). For example, a first die can produce a cushion with a harder bolster region and a softer central seating region, as shown in Figure 24, and a second die can produce a cushion with a hardness gradient from a first surface to a second surface, as shown in Figure 25.

[0242] The die 500 includes a solid body 502 that defines a plurality of orifices 504. In one or more embodiments, the plurality of orifices 504 may include at least 50 orifices, more preferably at least 500 orifices, and even more preferably at least 1000 orifices. For example, FIG. 29 illustrates a die having at least 1200 orifices. FIGS. 30 and 31 illustrate cross-sectional views of the breaker plate of FIG. 29. As illustrated, each orifice may taper from a larger orifice to a smaller orifice, which may generate more pressure to eject the flowable polymer strands from the die. The ejection system 600 applies pressure to eject the polymer resin 602 through the orifices 504 of the die 500. Thus, the size, arrangement, distribution, and density of the orifices 504 affect the characteristics and / or attributes of the cushion, such as overall shape, hardness, bulk density, average strand diameter, and strand shape. In a modified embodiment, the plurality of orifices 504 includes at least a first group of orifices 506 having a different size, distribution, density and / or shape than a second group of orifices 508. In a variation, a third group of orifices 510 has a different size, distribution, density and / or shape than the first group of orifices and / or the second group of orifices.

[0243] Each of the orifices has an average diameter and an orifice density (i.e., the first orifice group has a first average diameter and a first orifice density, the second orifice group has a second average diameter and a second orifice density, and the third orifice group has a third average diameter and a third orifice density). In refinements, the first average diameter can be different from the second and / or third average diameters and / or the first orifice density can be different from the second and / or third average densities. In variations, the first and third average diameters and / or orifice densities are the same or substantially the same (i.e., within manufacturing tolerances, within 1%, 1.5%, 3%, 5% or 10%). In another variation, the first average diameter can be smaller than the second average diameter, and the second average diameter can be smaller than the third average diameter. Alternatively, or in combination, the first orifice density may be less than the second orifice density, and the second orifice density may be less than the third orifice density.

[0244] In refined embodiments, the first average diameter is at least 1.2 mm, more preferably at least 1.4 mm, or even more preferably at least 1.6 mm. For example, the first average diameter may be 0.8 mm to 10 mm, or more preferably 1 mm to 5 mm, or even more preferably 1.2 mm to 3 mm. In some embodiments, the first orifice density may be at least 11.5 per square inch, or more preferably at least 13 per square inch, or even more preferably at least 15 per square inch. For example, the first orifice density may be 10 to 20 per square inch, or more preferably 11 to 18 per square inch, or even more preferably 12 to 16 per square inch. Alternatively, the first average diameter may be 1.2 mm or less, or more preferably 1.0 mm or less, or even more preferably 0.8 mm or less. For example, the first average diameter may be 0.05 to 1.2 mm, or more preferably 0.3 to 1.0 mm, or even more preferably 0.7 to 0.9 mm. In some embodiments, the first orifice density may be 11.5 or less per square inch, or more preferably 10 or less per square inch, or even more preferably 8 or less per square inch. For example, the first orifice density may be 1 to 11.5 orifices per square inch, or more preferably 3 to 10 or more preferably 5 to 8 orifices per square inch.

[0245] In refined embodiments, the second average diameter is at least 0.8 mm, more preferably at least 0.9 mm, or more preferably at least 1.0 mm, and not more than 1.6 mm, or more preferably not more than 1.5 mm, or even more preferably not more than 1.4 mm. For example, the second average diameter is 0.8 to 1.6 mm, or more preferably 0.9 to 1.5 mm, or even more preferably 1.0 to 1.4 mm. In some embodiments, the second orifice density is at least 9 per square inch, or more preferably at least 10 per square inch, or more preferably at least 11 per square inch, and not more than 14, or more preferably not more than 13 per square inch, or even more preferably 12 per square inch. For example, the second orifice density is 9 to 14 per square inch, or more preferably 10 to 13 per square inch, or even more preferably 11 to 12 per square inch.

[0246] In refined embodiments, the third average diameter is at least 1.2 mm, more preferably at least 1.6 mm, or even more preferably at least 1.8 mm. For example, the third average diameter is 1.2 to 10 mm, or more preferably 1.6 to 8 mm, or even more preferably 1.8 to 5 mm. In some embodiments, the third orifice density is at least 11.5 orifices per square inch, or more preferably at least 13 orifices per square inch, or even more preferably at least 15 orifices per square inch. For example, the third orifice density may be 10 to 20 orifices per square inch, or more preferably 11 to 18 orifices per square inch, or even more preferably 12 to 16 orifices per square inch.

[0247] In a variant, the orifices may form one or more gradients in terms of their distribution (i.e. orifice density) and / or size (e.g. average diameter). The gradients may correspond to those described above for the cushion. For example, the orifices proximate the first end of the die 500 may be more numerous and have a continuously decreasing size as one moves away from the first end toward the second end, where the smallest orifices are located. Alternatively, the orifices at the periphery may be smaller and the orifices at the central or intermediate portion may be larger. In another example, the first group of orifices proximate the first end of the die 500 may be densely packed or arranged to have a higher orifice density, and the density or orifice density may continuously decrease as one moves away from the first end toward the second end, which is the least densely packed or has the lowest orifice density. Alternatively, the orifices at the periphery may be less densely packed or have a lower orifice density than the orifices at the central or intermediate portion.

[0248] 27, the die 500 is disposed within a discharge system 600. In one embodiment, the discharge system 600 includes an inlet 601, such as a hopper, for receiving polymer resin 602, such as in a solid pelletized form. In a modified embodiment, the polymer resin 602 is sheared and heated, such as by an extruder 604, which melts the solid polymer resin 602 into a flowable form, such as molten polymer resin 602, prior to discharging from the die 500. In one embodiment, the extruder 604 may be driven by a motor 606 and a transmission 608. In a modified embodiment, the extruder 604 includes a screw 612 disposed within a barrel 614. In one or more embodiments, the die 500 is disposed and / or positioned at the end of the extruder 604 so that it can be easily removed and replaced with another die.

[0249] Referring to FIG. 8, the flowable molten polymer resin 131 is discharged from the die 500 as a filament and flows linearly into, through, and then into a second medium 139, such as water. In a modified embodiment, the first medium 135 and the second medium 139 have different densities such that deflection (i.e., the linear filaments change direction) occurs at or near the medium interface 137. For example, the second medium 139 can have a higher density than the first medium 135. In a variant, the second medium 139 is cooled to a temperature below the melting point and / or glass transition temperature of the polymer resin. In a modified embodiment, the second medium 139 can have a higher heat capacity than the first medium 135. The deflection or change in direction, along with the cooling effect of the second medium 139, can result in entanglement and / or intertwining of the polymer filaments. The polymer threads can solidify such that the entangled / entangled mass is a single piece, component, unit, and / or generally retains its shape, such as the shape of a cushion. In one or more embodiments, the entangled / entangled mass of polymer threads can exhibit elastic properties similar to foams and / or textiles. In modified embodiments, the entangled / entangled mass can be washed and / or dried after being removed from the second medium 139. Once cured, the threads can be generally fixed in position relative to one another such that they can become more proximal or distal depending on the pressure applied to them, but generally do not change their position relative to one another. Thus, portions with a greater bulk density and / or greater dimensions can exhibit a greater overall stiffness, and portions with a lesser bulk density and / or dimensions can exhibit a lesser overall stiffness.

[0250] As shown in FIG. 28, a method 800 for manufacturing a seat cushion or pad is disclosed. In one or more embodiments, the method 800 includes discharging a plurality of polymer strands from a die through a media interface to form a cushion (i.e., step 810), removing the cushion from a second media (i.e., step 820), and drying the cushion (i.e., step 830). In a modified embodiment, the discharging is performed by an extruder, as shown in FIG. 8. The extruder is configured to receive a polymer resin, such as a thermoplastic polymer resin. In a variant, the extruder includes a hopper for receiving the polymer resin. For example, pellets or beads of the polymer resin can be loaded into the hopper. The hopper can direct the polymer resin into a chamber / barrel, and a drive such as a screw can shear the polymer resin. In a modified embodiment, the chamber / barrel and / or a portion thereof is heated. The combination of shear and heat causes the solid pelletized polymer resin to become a flowable molten polymer material. For example, the chamber / barrel is heated to a temperature above the melting point of the resin.

[0251] The molten polymer strand may be discharged into a first medium, such as air. In an improved embodiment, the strand is discharged from a die, such as a breaker plate, having portions with different orifice densities and / or orifice sizes. In a variant, the breaker plate includes a gradient, such as an orifice density gradient and / or an orifice size gradient. In an improved embodiment, the breaker plate is a replaceable component of the extruder, and a first die / breaker plate is used to produce a first plurality of components and is replaced with a second die / breaker plate used to produce a second plurality of components different from the first plurality of components. The die 500 may be arranged to further direct the polymer strand in a linear motion into the second medium by gravity. In an improved embodiment, the second medium is denser than the first medium. The media define a medium interface between them. For example, the first medium may be a gas and the second medium may be a liquid, such as water. This difference causes deflection (e.g., bending) of the polymer strands at or near the media interface. The random deflection of the various polymer strands causes entanglement of the multiple polymer strands. The intertwined and entangled polymer strands are cooled by the second media to harden and transition from the molten state. In an improved embodiment, the mass of hardened intertwined / entangled polymer strands can form a non-foamed / unfoamed cushion. In an alternative embodiment, the mass (e.g., cushion) is removed from the second media and dried. Given the portions of the die with different properties, the cushion can have different attributes, such as harder and softer regions. In an improved embodiment, the different hardness is the result of different bulk densities and / or thread diameters.

[0252] A non-foam seat cushion is described that includes a plurality of entangled polymer strands having a first group of entangled polymer strands having a first hardness and a second group of entangled polymer strands having a second hardness different from the first hardness, the first and second groups of entangled polymer strands being interlocked.

[0253] In some embodiments, a first set of entangled polymer threads has a first average diameter and a second set of entangled polymer threads has a second average diameter that is different from the first average diameter.

[0254] In some embodiments, a first set of entangled polymer threads defines a first bulk density and a second set of entangled polymer threads has a second bulk density that is different from the first density.

[0255] In some embodiments, the first hardness is less than the second hardness, and the first hardness is less than or equal to 5 kPa.

[0256] In some embodiments, the second hardness is at least 5 kPa.

[0257] In some embodiments, the non-foam seat cushion further includes a third entangled polymer strand group from the plurality of entangled polymer strands having a third hardness, the second entangled polymer strand group being disposed between the first entangled polymer strand group and the third entangled polymer strand group, the first hardness being less than the second hardness and the third hardness being greater than the second hardness.

[0258] In some embodiments, the plurality of intertwined polymer threads form a stiffness gradient from a first region of the cushion to a second region of the cushion.

[0259] A vehicle seat assembly, e.g., 400, is described below. The vehicle seat assembly, e.g., 400, includes a seat frame, e.g., 402, that supports a non-foam cushion of any of the above-mentioned technologies.

[0260] A die, such as a breaker plate (e.g., 500), is described. The die (e.g., breaker plate 500) includes a solid body defining a plurality of orifices, the plurality of orifices (e.g., 504) having a first group of orifices (e.g., 506) and a second group of orifices (e.g., 508), the first group of orifices (e.g., 506) present at a first orifice density and having a first average diameter, and the second group of orifices (e.g., 508) present at a second orifice density and having a second average diameter, the first orifice density being different from the second orifice density and / or the first average diameter being different from the second average diameter.

[0261] In some embodiments, the first orifice density is different from the second orifice density.

[0262] In some embodiments, the first average diameter is different from the second average diameter.

[0263] In some embodiments, the first orifice density is less than or equal to 11.5 orifices per square inch.

[0264] In some embodiments, the first average diameter and the second average diameter differ by at least 0.4.

[0265] In some embodiments, the first orifice density and the second orifice density are at least 3.0 kg / m 3 different.

[0266] A system for discharging a polymer resin is described that includes an extruder equipped with a breaker plate (e.g., 500) of any of the above-described techniques, such that during operation, the extruder extrudes strands of polymer resin through a plurality of orifices (e.g., 504).

[0267] A method 220 of manufacturing a seat pad is described, which includes discharging molten polymer resin through a die (e.g., 500) defining a plurality of orifices (e.g., 504) to discharge a plurality of polymer strands into a media interface defined by a first medium and a second medium, where at least a portion of the polymer strands are deflected, entangled, and cured to form a non-foam cushion within the second medium 222.

[0268] The method 220 includes removing 224 the non-foam cushion from the second medium. The method 220 includes drying 226 the non-foam cushion. The plurality of orifices includes (i) a first group of orifices (e.g., 506) arranged at a first density and defining a first average diameter, and (ii) a second group of orifices (e.g., 508) arranged at a second density and defining a second average diameter, where the first density is different from the second density and / or the first average diameter is different from the second average diameter, such that the non-foam cushion has a first region having a first firmness and a second region having a second firmness different from the first firmness.

[0269] In some embodiments, the multiple orifices (eg, 504) are defined by a replaceable breaker plate.

[0270] In some embodiments, the multiple orifices (eg, 504) are arranged to form a size and / or distribution gradient such that the non-foam cushion has a firmness gradient.

[0271] In some embodiments, the plurality of orifices (e.g., 504) includes a third group of orifices (e.g., 510), and the non-foam cushion has a third region having a third hardness greater than a second hardness greater than the first hardness, and the second region is disposed between the first region and the third region.

[0272] In some embodiments, the plurality of orifices (e.g., 504) includes a third group of orifices, and the non-foam cushion has a third region having a third hardness, the third hardness being different from the second hardness and within 10% of the first hardness, and the second region being disposed between the first region and the third region.

[0273] Although exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms in accordance with the disclosure. In this regard, it will be understood that the terms used herein are terms of description rather than limitation, and that various modifications can be made without departing from the spirit and scope of the disclosure. Moreover, features of various embodiments can be combined to form further embodiments in accordance with the disclosure.

[0274] Section 1. A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to a molten state such that the polymeric material becomes a molten polymer; introducing the molten polymer into a die plate having a first region including a plurality of first holes extending therethrough and a second region including a plurality of second holes extending therethrough, the plurality of first holes collectively defining a first open space per unit area in the first region and the plurality of second holes collectively defining a second open space per unit area in the second region, the first open space per unit area being greater than the second open space per unit area; and cooling the molten polymer after it exits the die plate.

[0275] 2. The method of claim 1 or any of the following claims, wherein the number of the first holes per unit area in the first region is greater than the number of the second holes per unit area in the second region.

[0276] Clause 3. The method of any preceding or succeeding clause, wherein the diameter of the first hole is greater than the diameter of the second hole.

[0277] Clause 4. The method of any preceding or succeeding clause, producing a cushion blank by cooling the polymer after it exits the die plate, the method further comprising shielding a portion of the die plate with a template having a predetermined contour such that the cushion blank has a cross-section defined by the predetermined contour.

[0278] Clause 5. The method of any preceding or following clause, wherein the second region includes a location within the cushion blank that corresponds to a location of an occupant sensor.

[0279] Clause 6. The method of any preceding or succeeding clause, including two of the first regions, each located in a position corresponding to a respective bolster region of the cushion blank.

[0280] Clause 7. The method of any preceding or succeeding clause, wherein the die plate has a third region including a plurality of third holes extending therethrough, the plurality of third holes together defining a third open volume per unit area within the third region, the third open volume per unit area being less than the second open volume per unit area.

[0281] Clause 8. A vehicle interior part formed by the method of any of the preceding or following clauses.

[0282] Clause 9. A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to a molten state such that the polymeric material becomes a molten polymer; introducing the molten polymer into a die plate including a first region having an open portion and a closed portion and a second region having an open portion and a closed portion, wherein a ratio of the open portion of the first region to the open portion of the first region is greater than a ratio of the open portion of the second region to the open portion of the second region; and cooling the molten polymer after it exits the die plate.

[0283] Clause 10. The method of any preceding or succeeding clause, wherein the first region includes a plurality of first holes defining the open portion of the first region, the second region includes a plurality of second holes defining the open portion of the second region, and a number of the first holes per unit area of ​​the first region is greater than a number of the second holes per unit area of ​​the second region.

[0284] Clause 11. The method of any preceding or following clause, wherein the first region includes a plurality of first holes defining the open portion of the first region, and the second region includes a plurality of second holes defining the open portion of the second region, the first holes having a larger diameter than the second holes.

[0285] Clause 12. The method of any preceding or following clause, wherein the vehicle interior component includes a cushion blank having a cross-section, the method further including shielding a portion of the die plate with a template having a contour that defines the cross-section of the cushion blank.

[0286] Clause 13. The method of any of the preceding or following clauses, wherein the die plate includes a plurality of the first regions, each positioned at a location corresponding to a respective bolster region of the cushion blank.

[0287] Clause 14. The method of any preceding or following clause, wherein the second region includes a location within the cushion blank configured to receive an occupant sensor.

[0288] Clause 15. The method of any of the preceding or following clauses, wherein the die plate further comprises a third region having an open portion and a closed portion, and a ratio of the open portion of the second region to the second region is greater than a ratio of the open portion of the third region to the third region.

[0289] Clause 16. A die plate apparatus usable to manufacture a vehicle interior part, comprising: a plate including a first region including a plurality of first holes extending therethrough and a second region including a plurality of second holes extending therethrough, the plurality of first holes collectively defining a first opening in the first region and the plurality of second holes collectively defining a second opening in the second region, wherein a ratio of the first opening to the first region is greater than a ratio of the second opening to the second region.

[0290] Clause 17. The die plate apparatus of any preceding or succeeding clause, wherein the number of the first holes per unit area in the first region is greater than the number of the second holes per unit area in the second region.

[0291] Clause 18. The die plate apparatus of any preceding or following clause, wherein the diameter of the first hole is greater than the diameter of the second hole.

[0292] Clause 19. The die plate apparatus of any preceding or following clause, further comprising a template configured to cover at least a portion of the first plurality of holes, at least a portion of the second plurality of holes, or at least a portion of the first plurality of holes and the second plurality of holes, the template having a predetermined contour defining a cross-section of a portion of the vehicle interior part.

[0293] Clause 20. The die plate apparatus of any of the preceding or following clauses, wherein the vehicle interior part is a seat cushion, and the plate includes two of the first regions, each of which is disposed at a position corresponding to a respective bolster region of the seat cushion.

[0294] Clause 21. A method of making a product, comprising: discharging molten thermoplastic resin through a tool having an opening sized to fit a circumference of a product, the tool generating a plurality of strands through the opening while maintaining the plurality of strands within the circumference of the product; and providing resistance to the flow of the plurality of strands, thereby bending the strands so that the bent strands cross as a single nonwoven body in the shape of the circumference of the product.

[0295] Clause 22. The method of any preceding or following clause, further comprising cooling the plurality of strands as a single nonwoven product.

[0296] Clause 23. The method of any preceding or following clause, comprising: dispensing the molten thermoplastic resin from a plurality of nozzles, the plurality of nozzles having a combined area greater than an area of ​​the opening; and closing a subset of the plurality of nozzles outside the area of ​​the opening.

[0297] Clause 24. The method of any preceding or following clause, further comprising providing a plate as the tool.

[0298] Clause 25. The method of any preceding or following clause, further comprising cooling the tool.

[0299] Clause 26. The method of any preceding or following clause, further comprising providing as the tool a die having the opening therein.

[0300] Clause 27. The method of any preceding or following clause, further comprising providing a cooling passage through the mold for cooling the single nonwoven product.

[0301] Clause 28. The method of any preceding or following clause, further comprising placing the mold in a cooling fluid to cool the single nonwoven product.

[0302] Clause 29: A product made by a process including: extruding molten thermoplastic resin through a tool having an opening sized to fit a circumference of a product, the tool generating a plurality of strands through the opening while maintaining the plurality of strands within the circumference of the product; and providing resistance to the flow of the plurality of strands, thereby bending the strands so that the bent strands cross as a single nonwoven fabric in the shape of the circumference of the product.

[0303] Clause 30. The article of any preceding or following clause, wherein the article further comprises a single nonwoven cushion.

[0304] Clause 31. The article of any preceding or following clause, wherein the article further comprises a concave contoured perimeter.

[0305] Clause 32. A tool including a tool body having an opening therethrough, the opening sized to fit a perimeter of a cushion, the opening configured to receive molten thermoplastic resin as a plurality of discharged strands, the opening configured to maintain the plurality of discharged strands within the perimeter of the cushion.

[0306] Clause 33. The tool of any preceding or following clause, wherein the through opening is shaped as a seat cushion, the through opening being configured to form a unitary nonwoven cushion.

[0307] Clause 34. The tool of any preceding or following clause, wherein the through openings are formed with a curvature, the through openings being configured to form a unitary nonwoven cushion having the curvature.

[0308] Clause 35. The tool of any preceding or following clause, wherein the through opening is provided with a plurality of curvatures having a radius of at least 12 millimeters.

[0309] Clause 36. The tool of any preceding or following clause, wherein the through opening is formed with a convex perimeter to form a concave surface in the cushion.

[0310] Clause 37. A system for manufacturing a cushion, the system comprising: a dispenser of molten thermoplastic resin; and a tool according to any preceding or following clause oriented relative to the dispenser to receive the molten thermoplastic resin.

[0311] Clause 38. The system of any preceding or succeeding clause, further comprising a fluid chamber for receiving the molten thermoplastic resin to provide resistance to the flow of the discharged strands so as to bend the strands and cross them into a single nonwoven body in the shape of a full periphery of the cushion.

[0312] Clause 39. The system of any preceding or following clause, wherein the tool is oriented within the fluid chamber for cooling the discharged strands as a single nonwoven cushion.

[0313] Clause 40. The system of any preceding or following clause, wherein cooling passages are formed through the tool to cool the discharged strands as the single nonwoven cushion.

[0314] Clause 41. A method comprising: extruding molten thermoplastic resin as a plurality of strands and at least one film; and providing resistance to flow of the extruded plurality of strands, wherein providing resistance comprises expanding the plurality of strands by crossing and bonding at least a subset of the plurality of strands to one another and to the at least one film.

[0315] Clause 42. The method of any preceding or following clause, further comprising cooling the plurality of filaments and the at least one film as a single product.

[0316] Clause 43. The method of any preceding or following clause, further comprising cooling the plurality of filaments and the at least one film with a fluid that provides resistance to flow of the plurality of filaments.

[0317] Clause 44. The method of any preceding or following clause, further comprising cooling the plurality of filaments in a fluid chamber.

[0318] Clause 45. The method of any preceding or following clause, further comprising dispensing the at least one film onto an exterior surface of the unitary body.

[0319] Clause 46. The method of any preceding or following clause, further comprising discharging the at least one film between at least two subsets of the plurality of filaments.

[0320] Clause 47. The method of any preceding or following clause, further comprising forming an opening through the at least one film.

[0321] Clause 48. The method of any preceding or following clause, wherein the discharging further comprises discharging the plurality of strands through a plurality of holes in the tool and discharging the at least one film through at least one slit in the tool.

[0322] Clause 49. The method of any preceding or following clause, comprising removing the tool from the extruder; attaching a second tool to the extruder; passing the molten thermoplastic resin through the second tool to extrude a second plurality of strands and a second film; and providing resistance to flow of the extruded second plurality of strands, wherein the providing resistance comprises expanding the second plurality of strands by causing at least a subset of the second plurality of strands to cross over one another and form the second film and a second unitary body different from the first unitary body.

[0323] Clause 50. The method of any preceding or following clause, further comprising assembling a seat with a cushion formed by the method.

[0324] 51. Products formed by a process in any of the preceding or following paragraphs.

[0325] Clause 52. An article formed by a process comprising: extruding molten thermoplastic resin as a plurality of strands and at least one film; and providing resistance to flow of the extruded plurality of strands, the providing resistance including expanding the plurality of strands by causing at least a subset of the plurality of strands to cross one another and merge with the at least one film.

[0326] Clause 53. An article formed by the method of any preceding or following clause, further comprising forming at least one film on an outer surface of the unitary body.

[0327] Clause 54. An article formed by the method of any preceding or following clause, further comprising forming the at least one film between at least two subsets of the plurality of strands as an impermeable film.

[0328] Clause 55. An article formed by the method of any preceding or following clause, further comprising forming an opening through the at least one film.

[0329] Clause 56. A seat assembly made by a process comprising assembling a seat having a cushion formed by a method according to any preceding or following clause.

[0330] Clause 57. A seat assembly manufactured by the method of any preceding or following clause, further comprising attaching at least one of a seat trim, an actuator and / or a heat transfer layer to the at least one film.

[0331] Clause 58. An article comprising an expanded network of a plurality of interconnected thermoplastic filaments and at least one thermoplastic film integrally bonded as a unitary body to at least a subset of the plurality of filaments.

[0332] Clause 59. The article of any preceding or following clause, wherein the at least one film is stretched onto an outer surface of the unitary body.

[0333] Clause 60. The article of any of the preceding or following clauses, wherein the at least one film is impermeable.

[0334] Clause 61. The article of any preceding or following clause, wherein the at least one film is stretched between at least two subsets of the plurality of filaments.

[0335] Clause 62. The article of any preceding or following clause, wherein an opening extends through the at least one film.

[0336] 63. A seat assembly comprising, as a seat cushion, a product according to any of the preceding or following paragraphs.

[0337] Clause 64. The seating assembly of any preceding or following clause, further comprising at least one of a seat trim, an actuator, and / or a heat transfer layer attached to the at least one film.

[0338] Clause 65: A tool including a body having a plurality of openings formed therethrough and at least one slit formed therethrough, the tool being configured to dispense molten thermoplastic resin through the plurality of openings and the at least one slit.

[0339] Clause 66: A system comprising an extruder of molten thermoplastic resin and a tooling of any preceding or following clause attached to the extruder, the system being configured to pass the molten thermoplastic resin through the tooling and extrude it into a plurality of filaments and at least one film.

[0340] Clause 67. A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to a molten state such that the polymeric material becomes a molten polymer; introducing the molten polymer into a die plate having a plurality of holes disposed therethrough and passing the molten polymer through the plurality of holes to form a plurality of molten polymer filaments; surrounding the molten polymer filaments with a heating device operable to apply heat to the molten polymer filaments; introducing the molten polymer filaments into a tank and cooling the molten polymer filaments to form an interconnected filament structure.

[0341] Clause 68. The method of any preceding or following clause, wherein the heating device includes a rectangular heating structure that surrounds the molten polymer filaments as they emerge from the die plate.

[0342] Clause 69. The method of any preceding or following clause, wherein the die plate includes a plurality of sides, and the heating device is attached to each of the plurality of sides of the die plate.

[0343] Clause 70. The method of any preceding or following clause, wherein the heating device is configured to control an ambient temperature around the molten polymer filaments to a temperature between 60°C and 140°C.

[0344] Clause 71. The method of any preceding or following clause, wherein the heating device is positioned at least 100 mm to 150 mm from the molten polymer filaments.

[0345] Clause 72. The method of any preceding or following clause, wherein the molten polymer filaments include an outer portion disposed on a side of an outer edge of the die plate and an inner portion disposed inward from the outer portion, and the heating device is configured to heat the outer portion such that bonds between the molten polymer filaments in the outer portion are greater than bonds between the molten polymer filaments in the inner portion.

[0346] Clause 73. The method of any preceding or following clause, wherein the molten polymer is a first molten polymer including a first material and the molten polymer filament is a first molten polymer filament, the method further comprising introducing a second molten polymer including a second material into the die plate and passing the second molten polymer through the plurality of holes in the die plate to form a plurality of second molten polymer filaments.

[0347] Clause 74. The method of any preceding or following clause, wherein the first molten polymer is introduced into the die plate on an outer edge side of the die plate and the second molten polymer is introduced into the die plate inwardly from the first molten polymer such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

[0348] Clause 75. An interior vehicle part formed by a method according to any of the preceding or following clauses.

[0349] Clause 76. A method of manufacturing a vehicle interior part, comprising: heating a first polymer material to a molten state to produce a first molten polymer; extruding the first molten polymer to form a plurality of first molten polymer filaments; heating an entire periphery of the first molten polymer filaments; and cooling the molten first polymer filaments in a fluid bath to form an interconnected filament structure.

[0350] Clause 77. The method of any preceding or following clause, wherein the first molten polymer comprises a first material, the method further comprising extruding a second molten polymer comprising a second material to form a plurality of second molten polymer filaments.

[0351] Clause 78. The method of any preceding or following clause, wherein the first molten polymer and the second molten polymer are extruded such that the first molten polymer filament at least partially surrounds the second molten polymer filament.

[0352] Clause 79. The method of any preceding or following clause, wherein heating an entire circumference of the first molten polymer filament includes heating the first molten polymer filament on four sides of the first molten polymer filament.

[0353] Clause 80. The method of any preceding or following clause, wherein heating the entire circumference of the first molten polymer filament comprises heating the first molten polymer filament to a temperature of 60°C to 140°C.

[0354] Clause 81. The method of any preceding or following claim, wherein an entire circumference of the first molten polymer filaments is heated such that bonds between the first molten polymer filaments are greater than bonds between the second molten polymer filaments.

[0355] 82. A vehicle interior part formed by a method according to any of the preceding or following paragraphs.

[0356] Clause 83: A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to produce a molten polymer; forming a plurality of molten polymer filaments from the molten polymer by extruding the molten polymer through a die plate; heating a periphery of the molten polymer filaments with a heating device; and cooling the molten polymer filaments in a fluid bath to form an interconnected filament structure.

[0357] Clause 84. The method of any preceding or following clause, wherein the heating device is attached to the die plate.

[0358] Clause 85. The method of any preceding or following clause, wherein the molten polymer is a first molten polymer including a first material and the molten polymer filaments are first molten polymer filaments, the method further comprising introducing a second molten polymer including a second material into the die plate and passing the second molten polymer through the die plate to form a plurality of second molten polymer filaments.

[0359] Clause 86. The method of any preceding or following clause, wherein the first molten polymer is introduced into the die plate on an outer edge side of the die plate and the second molten polymer is introduced into the die plate inward from the first molten polymer such that the second molten polymer filaments at least partially surround the first molten polymer filaments.

[0360] Clause 87: A vehicle seat cushion component, comprising: a plastic mesh base including a first plurality of three-dimensional filament annuli comprised of a first thermoplastic polymer, the plastic mesh base having a first side edge, a second side edge, a leading edge, a trailing edge, a first surface, and a second surface; a first bolster including a second plurality of three-dimensional filament annuli comprised of a second thermoplastic polymer different from the first thermoplastic polymer, the first bolster attached to the plastic mesh base at the first side edge, and a second bolster attached to the plastic mesh base at the second side edge.

[0361] Clause 88. The vehicle seat cushion component of any preceding or following clause, wherein the second bolster includes a third plurality of three-dimensional filament annuli comprised of the second thermoplastic polymer.

[0362] Clause 89. The vehicle seat cushion component of any preceding or following clause, wherein the second bolster includes a third plurality of three-dimensional filament annuli composed of a third thermoplastic polymer different from the first thermoplastic polymer.

[0363] Clause 90. The vehicle seat cushion component of any preceding or following clause, wherein the second bolster includes a third plurality of three-dimensional filament annuli composed of a third thermoplastic polymer different from the first and second thermoplastic polymers.

[0364] Clause 91. The vehicle seat cushion component of any preceding or following clause, wherein the second bolster includes a third plurality of three-dimensional filament annuli composed of a third thermoplastic polymer different from the first thermoplastic polymer.

[0365] Clause 92. The vehicle seat cushion component of any preceding or following clause, wherein the third bolster includes a fourth plurality of three-dimensional filament annuli, the fourth plurality of three-dimensional filament annuli being composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0366] Clause 93. The vehicle seat cushion component of any preceding or following clause, wherein the plurality of three-dimensional filamentary annuli includes a plurality of fusion connections where two annuli are attached to one another.

[0367] Clause 94. The vehicle seat cushion component of any preceding or following clause, wherein at least a subset of the annuli in the plurality of three-dimensional filament annuli are not parallel or aligned with one another.

[0368] Clause 95. The vehicle seat cushion component of any preceding or following clause, wherein the annuli within the plurality of three-dimensional filament annuli are randomly oriented.

[0369] Clause 96. The vehicle seat cushion component of any preceding or following clause, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

[0370] Clause 97. The vehicle seat cushion component of any preceding or following clause, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0371] Clause 98. The vehicle seat cushion component of any preceding or following clause, wherein the thermoplastic polymer comprises a first linear low density polyethylene.

[0372] Clause 99. The vehicle seat cushion component of any preceding or following clause, wherein the thermoplastic polymer comprises a second linear low density polyethylene different from the first linear low density polyethylene.

[0373] Clause 100. A seat assembly comprising a frame and a cushion according to any preceding or following clause supported by the frame.

[0374] Clause 101. A tool including a die, the die defining a series of openings arranged to extrude material for a threaded mesh material member for a cushion according to any of the preceding or following clauses, the series of openings arranged to define an outer periphery of the member to define the plastic mesh base, the first bolster, and the second bolster.

[0375] Clause 102. The tool of any preceding or following clause, wherein the series of openings is further configured such that the periphery defines the bolster.

[0376] Clause 103: A method, comprising: extruding a first thermoplastic polymer to form a plastic mesh base having a first side edge, a second side edge, a leading edge, a trailing edge, a first face, and a second face, the plastic mesh base including a first plurality of three-dimensional filament loops; extruding a second thermoplastic polymer, different from the first thermoplastic polymer, to form a first bolster attached to the plastic mesh base at the first side edge, the first bolster including a second plurality of three-dimensional filament loops; and extruding material to form a second bolster attached to the plastic mesh base at the second side edge.

[0377] Clause 104. The method of any preceding or following clause, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of the second thermoplastic polymer.

[0378] Clause 105. The method of any preceding or following clause, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being composed of a third thermoplastic polymer different from the first thermoplastic polymer.

[0379] Clause 106. The method of any preceding or following clause, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a third thermoplastic polymer different from the first and second thermoplastic polymers.

[0380] Clause 107. The method of any preceding or following clause, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being composed of a third thermoplastic polymer different from the first thermoplastic polymer.

[0381] Clause 108. The method of any preceding or following clause, further comprising a third bolster, the third bolster comprising a fourth plurality of three-dimensional filament loops, the fourth plurality of three-dimensional filament loops being comprised of a fourth thermoplastic polymer different from the first thermoplastic polymer.

[0382] Clause 109: A non-foam seat cushion comprising a plurality of entangled polymer strands, the plurality of entangled polymer strands having a first group of entangled polymer strands having a first hardness and a second group of entangled polymer strands having a second hardness different from the first hardness, the first group of entangled polymer strands and the second group of entangled polymer strands being connected.

[0383] Clause 110. The non-foam seat cushion of any preceding or following clause, wherein the first group of entangled polymer strands has a first average diameter and the second group of entangled polymer strands has a second average diameter different from the first average diameter.

[0384] Clause 111. The non-foam seat cushion of any preceding or following clause, wherein the first set of entangled polymer strands has a first bulk density and the second set of entangled polymer strands has a second bulk density that is different from the first density.

[0385] Clause 112. The non-foam seat cushion of any preceding or following clause, wherein the first hardness is less than the second hardness, and the first hardness is 5 kPa or less.

[0386] Clause 113. The non-foam seat cushion of any preceding or following clause, wherein the second hardness is at least 5 kPa.

[0387] Clause 114. The non-foam seat cushion of any preceding or following clause, further comprising a third entangled polymer strand group from the plurality of entangled polymer strands having a third hardness, the second entangled polymer strand group being disposed between the first entangled polymer strand group and a third entangled polymer strand group, the first hardness being less than the second hardness and the third hardness being greater than the second hardness.

[0388] Clause 115. The non-foam seat cushion of any preceding or following clause, wherein the plurality of intertwined polymeric filaments have a hardness gradient from a first region of the cushion to a second region of the cushion.

[0389] Clause 116. A vehicle seat assembly including a seat frame supporting a non-foam cushion according to any preceding or following clause.

[0390] Clause 117: A breaker plate having a solid body defining a plurality of orifices, the plurality of orifices having a first group of orifices and a second group of orifices, the first group of orifices being present at a first orifice density and having a first average diameter, the second group of orifices being present at a second orifice density and having a second average diameter, the first orifice density being different from the second orifice density, and / or the first average diameter being different from the second average diameter.

[0391] Clause 118. The breaker plate of any preceding or following clause, wherein the first orifice density is different from the second orifice density.

[0392] Clause 119. The breaker plate of any preceding or following clause, wherein the first average diameter is different from the second average diameter.

[0393] Clause 120. The breaker plate of any preceding or following clause, wherein the first orifice density is 11.5 or less per square inch.

[0394] Item 121. The breaker plate of any preceding or following item, wherein the first average diameter and the second average diameter differ by at least 0.4.

[0395] Item 122: The first orifice density and the second orifice density are at least 3.0 kg / m 3 13. A breaker plate according to any preceding or following claim, differing only in

[0396] Clause 123: A system for discharging a polymer resin, comprising an extruder having disposed thereon a breaker plate according to any preceding or following clause, the extruder being configured to extrude filaments of the polymer resin through the plurality of orifices during operation.

[0397] Clause 124. A method of making a seat pad, comprising: discharging a molten polymer resin through a die defining a plurality of orifices to discharge a plurality of polymer strands at a medium interface defined by a first medium and a second medium to deflect, entangle, and harden at least a portion of the polymer strands to form a non-foam cushion in the second medium; removing the non-foam cushion from the second medium; and drying the non-foam cushion, wherein the plurality of orifices includes (i) a first group of orifices arranged at a first density and defining a first average diameter, and (ii) a second group of orifices arranged at a second density and defining a second average diameter, wherein the first density is different from the second density and / or the first average diameter is different from the second average diameter, and wherein the non-foam cushion has a first region having a first hardness and a second region having a second hardness different from the first hardness.

[0398] Clause 125. The method of any preceding or following clause, wherein the plurality of orifices are defined by a replaceable breaker plate.

[0399] Clause 126. The method of any preceding or following clause, wherein the plurality of orifices are arranged to form a size and / or distribution gradient such that the non-foam cushion has a firmness gradient.

[0400] Clause 127. The method of any preceding or following clause, wherein the plurality of orifices includes a third group of orifices such that the non-foam cushion has a third region having a third hardness greater than the second hardness greater than the first hardness, the second region being disposed between the first region and the third region.

[0401] Clause 128. The method of any preceding or following clause, wherein the plurality of orifices includes a third group of orifices such that the non-foam cushion has a third region having a third hardness different from the second hardness and within 10% of the first hardness, the second region being disposed between the first region and the third region.

[0402] Clause 129: A cushion for a vehicle seat or the like, comprising a (e.g., nonwoven) meshwork comprising a plurality of interconnected polymer filaments, the plurality of interconnected polymer filaments comprising (i) a first polymer filament subset and a second polymer filament subset that is different (e.g., has a different composition, hardness, density, shape, size, and / or thickness) from the first polymer filament subset, and / or (ii) at least a portion of the interconnected polymer filaments are bonded to a polymer film.

[0403] Clause 130. The cushion of any preceding or following clause, wherein the first and second subsets are interconnected.

[0404] 131. The cushion of any preceding or following clause, wherein: (a) the first subset has a first hardness and the second subset has a second hardness that is different from the first hardness; (b) the first subset has a first density and the second subset has a second density that is different from the first density; (c) the first subset has a first filament dimension (e.g., chain length / molecular weight / average diameter) and the second subset has a second filament dimension (e.g., chain length / molecular weight / average diameter); and / or (d) the first subset is formed from a first polymeric material (e.g., polyethylene) and the second subset is formed from a second polymeric material (e.g., polypropylene, polystyrene, polycarbonate, polyvinyl chloride) that is different from the first polymeric material.

[0405] Clause 132. The cushion of any preceding or following clause, wherein the first dimension is a first average (e.g., larger / thicker) diameter and the second dimension is a second average (e.g., smaller / thinner) diameter.

[0406] Clause 133. The cushion of any preceding or following clause, wherein the mesh has a contoured shape.

[0407] Clause 134. The cushion of any preceding or following clause, wherein the firmness is a bulk firmness.

[0408] Clause 135. The cushion of any preceding or following clause, wherein the cushion is non-foamed.

[0409] Clause 136. The cushion of any preceding or following clause, wherein the portion of the interconnected polymer filaments are integrally bonded to a polymer film.

[0410] Clause 137. The cushion of any preceding or following clause, wherein the interconnected polymer filaments and the polymer film are made of the same polymer material.

[0411] Clause 138. The cushion of any preceding or following clause, wherein the film forms a skin along the mesh.

[0412] Clause 139. The cushion of any preceding or following clause, wherein the mesh is a nonwoven fabric.

[0413] Clause 140. The cushion of any preceding or following clause, wherein the meshwork includes a base portion and an additional bolster portion.

[0414] Clause 141. The cushion of any preceding or following clause, wherein the first subset forms the base portion and the second subset forms the additional bolster portion.

[0415] Clause 142. The cushion of any preceding or following clause, wherein the base portion defines a first contour and the additional portion defines a second contour that is different from the first contour.

[0416] Clause 143. The cushion of any preceding or following clause, wherein the additional bolster portion includes a first bolster.

[0417] Clause 144. The cushion of any preceding or following clause, wherein the first bolster is attached to the base portion at a first edge of the base portion.

[0418] Clause 145. The cushion of any preceding or following clause, wherein the first bolster comprises the second polymer filament subset.

[0419] Clause 146. The cushion of any preceding or following clause, wherein the first polymer filament subset comprises a first polymer material and the second polymer filament subset comprises a second polymer material that is different from the first polymer material (e.g., different composition, shape, size).

[0420] Clause 147. The cushion of any preceding or following clause, wherein the additional bolster portion includes a second bolster.

[0421] Clause 148. The cushion of any preceding or following clause, wherein the second bolster is attached to the base portion at a second edge of the base portion.

[0422] Clause 149. The cushion of any preceding or following clause, wherein the second bolster opposes the first bolster.

[0423] Clause 150. The cushion of any preceding or following clause, wherein the second bolster includes a third polymer filament subset of the plurality of interconnected polymer filaments, the third polymer filament subset being different (e.g., different composition, shape, size) from the first polymer filament subset and / or the second polymer filament subset.

[0424] Clause 151. The cushion of any preceding or following clause, wherein the third polymer filament subset comprises a third polymer material different from the first polymer material and / or the second polymer material.

[0425] Clause 152. The cushion of any preceding or following clause, wherein the additional bolster portion includes a third bolster.

[0426] Clause 153. The cushion of any preceding or following clause, wherein the third bolster is attached to the base portion at a third edge of the base portion.

[0427] Clause 154. The cushion of any preceding or following clause, wherein the third edge is a rear edge of the base portion.

[0428] Clause 155. The cushion of any preceding or following clause, wherein the third bolster includes a fourth polymer filament subset different from the first, second, and / or third polymer filament subsets.

[0429] Clause 156. The cushion of any preceding or following clause, wherein the fourth polymer filament subset comprises a fourth polymer material different from the first, second, and / or third polymer materials.

[0430] Clause 157. The cushion of any preceding or following clause, wherein the additional bolster portion includes a fourth bolster.

[0431] Clause 158. The cushion of any preceding or following clause, wherein the fourth bolster is attached to the base portion at a fourth edge.

[0432] Clause 159. The cushion of any preceding or following clause, wherein the fourth bolster is opposed to the third bolster.

[0433] Clause 160. The cushion of any preceding or following clause, wherein the fourth edge is a front edge of the base portion.

[0434] Clause 161. The cushion of any preceding or following clause, wherein the fourth bolster includes a fifth polymer filament subset different from the first, second, third and / or fourth polymer filament subsets.

[0435] Clause 162. The cushion of any preceding or following clause, wherein the fifth polymer filament subset comprises a fifth polymer material different from the first, second, third and / or fourth polymer materials.

[0436] Clause 163. The cushion of any preceding or following clause, wherein the plurality of interconnected polymer filaments comprises a thermoplastic polymer.

[0437] Clause 164. The cushion of any preceding or following clause, wherein the density is bulk density.

[0438] Clause 165. The cushion of any preceding or following clause, wherein the first hardness is 5 kPa or less.

[0439] Clause 166. The cushion of any preceding or following clause, wherein the first hardness is less than the second hardness.

[0440] Clause 167. The cushion of any preceding or following clause, wherein the second firmness is at least 5 kPa.

[0441] Clause 168. The cushion of any preceding or following clause, wherein the plurality of interconnected polymer filaments includes a third polymer filament subset distinct from the first polymer filament subset and distinct from the second polymer filament subset.

[0442] Clause 169. The cushion of any preceding or following clause, wherein the third subset has a different hardness than the first and second subsets.

[0443] Clause 170. The cushion of any preceding or following clause, wherein the second subset is disposed between the first and third subsets.

[0444] Clause 171. The cushion of any preceding or following clause, wherein the first subset has a first hardness and the second subset has a second hardness, the first hardness being less than the second hardness and the third hardness being greater than the second hardness.

[0445] Clause 172. The cushion of any preceding or following clause, wherein the plurality of interconnected polymer filaments have a hardness gradient from a first region to a second region.

[0446] Clause 173. The cushion of any preceding or following clause, wherein the polymeric film is disposed to form an outer surface (e.g., a skin) of the mesh.

[0447] Clause 174. The cushion of any preceding or following clause, wherein the polymeric film is impermeable (e.g., to air or liquid).

[0448] Clause 175. The cushion of any preceding or following clause, wherein the polymeric film is disposed between a first portion of the polymeric filaments and a second portion of the polymeric filaments.

[0449] Clause 176. The cushion of any preceding or following clause, wherein the polymeric film defines an opening.

[0450] Clause 177. The cushion of any preceding or following clause, wherein the plurality of interconnected polymeric filaments includes a plurality of fusion connections at which at least two filaments are bonded to one another.

[0451] Clause 178. The cushion of any preceding or following clause, wherein at least a portion of the polymer filaments are not parallel or aligned.

[0452] Clause 179. The cushion of any preceding or following clause, wherein polymer filaments in the plurality of interconnected polymer filaments are randomly oriented.

[0453] Clause 180. The cushion of any preceding or following clause, wherein the plurality of interconnected polymer filaments comprises a polymer selected from the group consisting of polyolefins, polyethylene, polystyrene, polyester, polyurethane, and polyamide.

[0454] Clause 181. The cushion of any preceding or following clause, wherein the polyethylene is a low density polyethylene.

[0455] Clause 182. The cushion of any preceding or following clause, wherein the polyethylene is linear.

[0456] Clause 183. The cushion of any preceding or following clause, wherein the plurality of interconnected polymer filaments includes an additional polyethylene different from the first polyethylene.

[0457] Clause 184. The cushion of any preceding or following clause, wherein the cushion is a seat cushion.

[0458] Heading 185. A seat assembly including a frame supporting a cushion as claimed in any preceding or following heading.

[0459] Clause 186. A seat assembly as described in any preceding or following clause, wherein the seat assembly is a vehicle seat assembly.

[0460] Clause 187. The seat assembly of any preceding or following clause, further comprising a seat trim, an actuator and / or a heat transfer layer attached to the polymeric film.

[0461] Paragraph 188. A vehicle comprising a floor panel and a seat assembly as described in any preceding or succeeding paragraph attached to the floor panel.

[0462] Item 189: A die tool (e.g., a die / breaker plate and / or a funnel) having a solid body (e.g., a metal body) defining a first portion (e.g., a portion for forming a center seat cushion portion) that defines a first plurality of orifices (e.g., a first subset of nozzles / holes) so as to define a first open space (e.g., a collective open area of ​​holes) and a first closed portion, and a second portion (e.g., a portion for forming a bolster) that defines one or more orifices (e.g., a second subset of nozzles / holes) so as to define a second open space (e.g., a collective open area of ​​holes) and a second closed portion, comprising: (i) a first portion (e.g., a portion for forming a bolster) that defines a first plurality of orifices (e.g., a first subset of nozzles / holes) so as to define a first closed portion; A die tool comprising the body, wherein: (i) the first open space and the first closed portion are different (i.e., different orifice density / shape / size / different perimeter) from the second open space and the second closed portion; (ii) the orifices define a shape of a final product having a first contour and a second contour that is different from the first contour; (iii) one or more orifices include elongated orifices defining a polymer film; and / or (iv) the first plurality of orifices (e.g., a first subset) are different (e.g., in density, shape, size, quantity, etc.) from the one or more orifices (e.g., a second subset).

[0463] Clause 190. The die tool of any preceding or following clause, wherein the first portion (e.g., forming a central cushion portion) has a different orifice density (e.g., number of orifices per unit area) than the second portion (e.g., a bolster).

[0464] Clause 191. The die tool of any preceding or following clause, wherein the first plurality of orifices (e.g., a first subset) is of a different size (e.g., average diameter) than the one or more orifices (e.g., a second subset).

[0465] Clause 192. The die tool of any preceding or following clause, wherein a first plurality of orifices in the first portion (e.g., a first subset) have a different average diameter than the one or more orifices in the second portion (e.g., a second subset).

[0466] Clause 193. The die tool of any preceding or following clause, wherein the one or more orifices (e.g., a second subset) form at least one slit (e.g., a hole for forming a polymer film) through the solid body (e.g., a metal body).

[0467] Item 194. The die tool of any preceding or following item, wherein the orifice of the die tool is configured to eject molten thermoplastic resin.

[0468] Clause 195. The die tool of any preceding or following clause, wherein the one or more orifices are positioned to define a perimeter of a cushion having first and second bolsters.

[0469] Clause 196. The die tool of any preceding or following clause, wherein the one or more orifices is a second plurality of orifices.

[0470] Clause 197. The die tool of any preceding or following clause, wherein the first portion defines a first area, the first open space defines a first open area, the second portion defines a second area, and the second open space defines a second open area, and wherein the first open area to the first area defines a greater ratio than the second open area to the second area.

[0471] Clause 198. The die tool of any preceding or following clause, wherein the one or more orifices include a through opening sized to fit around a periphery of the cushion (e.g., to provide a skin along an outer edge).

[0472] Clause 199. The die tool of any preceding or following clause, wherein the through openings are configured to receive molten thermoplastic resin and expel it as a plurality of molten filaments.

[0473] Clause 200. The die tool of any preceding or following clause, wherein the through openings are configured to maintain the plurality of molten filaments.

[0474] Item 201. The die tool of any preceding or following item, wherein the first orifice density is 8 or less per square inch.

[0475] Item 202. The die tool of any preceding or following item, wherein the second orifice density is at least 9 orifices per square inch.

[0476] Item 203. The die tool of any preceding or following item, wherein the first average diameter and the second average diameter differ by at least 0.4 mm.

[0477] Clause 204. The die tool of any preceding or following clause, wherein the number of orifices per unit area in the first section is greater than the number of orifices per unit area in the second section.

[0478] Clause 205. The die tool of any preceding or following clause, further comprising a template configured to cover at least a portion of the plurality of orifices and / or one or more orifices (e.g., capable of being placed / covered over a portion of the die to define a cross-sectional shape of the final product).

[0479] Clause 206. The die tool of any preceding or following clause, wherein the template has a predetermined contour defining a cross-section of a portion of a vehicle interior part.

[0480] Clause 207. The die tool of any preceding or following clause, wherein the template has a predetermined contour that defines a cross-section of a portion of the cushion.

[0481] Clause 208. The die tool of any preceding or following clause, wherein the first portions are positioned in positions corresponding to respective bolster portions of the seat cushion.

[0482] Clause 209. The die tool of any preceding or following clause, wherein the through opening is formed as a seat cushion.

[0483] Clause 210. The die tool of any preceding or following clause, wherein the through openings are configured to form a unitary nonwoven cushion.

[0484] Clause 211. The die tool of any preceding or following clause, wherein the through openings are formed into a curved shape to form a unitary nonwoven cushion having a curvature.

[0485] Clause 212. The die tool of any preceding or following clause, wherein the through opening has a plurality of curvatures having a radius of at least 12 mm.

[0486] Clause 213. The die tool of any preceding or following clause, wherein the through opening is formed with a convex perimeter to form a concave surface of the cushion.

[0487] Clause 214: A dispensing system including a dispenser (e.g., an extruder) having a die tool as described in any preceding or following clause, wherein during operation, the dispenser dispenses molten thermoplastic resin through the orifices of the die tool.

[0488] Clause 215. The dispensing system of any preceding or following clause, wherein the dispenser is an extruder that extrudes the molten thermoplastic resin through the orifices of the die tool to form molten thermoplastic filaments.

[0489] Clause 216. The dispensing system of any preceding or following clause, further comprising a fluid chamber (e.g., a cooling bath) for receiving the molten thermoplastic filaments and providing resistance to the flow of the molten thermoplastic filaments to bend the filaments and cause the filaments to cross and / or bond to one another to form a unitary nonwoven body in the shape of the periphery of the cushion.

[0490] Clause 217. The dispensing system of any preceding or following clause, wherein the die tool is aligned with the fluid chamber to cool the molten thermoplastic filaments into a single nonwoven cushion.

[0491] Item 218. The discharge system of any preceding or following item, wherein the die tool defines cooling passages formed therethrough for cooling the molten thermoplastic filaments as a single nonwoven cushion.

[0492] Item 219. A vehicle interior part comprising a plurality of interconnected polymeric filaments extruded through a die tool according to any of the preceding or following items.

[0493] Item 220. A cushion comprising a plurality of interconnected polymeric filaments extruded through a die tool as described in any preceding or following item.

[0494] 221. A method, such as for manufacturing a vehicle seat cushion, comprising: discharging (e.g., extruding) a molten polymer resin through a die apparatus (e.g., a die plate, a template, and / or a funnel) having a first region defining a first plurality of openings (e.g., a first subset) for discharging molten polymer filaments and a second region defining one or more additional openings (e.g., a second subset) for discharging an additional molten polymer member (e.g., an additional filament and / or a film) different from the molten polymer filaments, the first region defining a first ratio of first closed area (e.g., a collective area of ​​holes) to first open area (e.g., a solid portion of a die plate) that is different from a second ratio of second closed area to second open area of ​​the second region; and cooling the molten polymer filaments and the additional molten polymer member to form a network (e.g., a nonwoven fabric) comprising interconnected polymer filaments, the network having a first portion different from a second portion.

[0495] Clause 222. The method of any preceding or following clause, wherein the mesh is a non-foam cushion.

[0496] Clause 223. The method of any preceding or following clause, wherein the mesh is a vehicle interior component.

[0497] Clause 224. The method of any preceding or following clause, wherein the additional molten polymeric members are additional polymeric filaments having different shapes, sizes, densities and / or compositions.

[0498] Clause 225. The method of any preceding or following clause, wherein the molten polymeric material is extruded through the die assembly.

[0499] Clause 226. The method of any preceding or following clause, wherein the first plurality of openings or the one or more additional openings define a perimeter of the shape of an end product (e.g., a vehicle seat cushion).

[0500] 227. The method of any preceding or following claim, wherein the final product is a seat cushion.

[0501] Item 228. The method of any preceding or following item, wherein the end product is a vehicle interior part.

[0502] Clause 229. The method of any preceding or following clause, wherein the first plurality of openings (e.g., a first subset of holes) defines a first contour that is different from a second contour defined by the one or more additional openings (e.g., a second subset of holes).

[0503] Item 230. The method of any preceding or following item, wherein the additional molten polymer member is a polymer film.

[0504] Item 231. The method of any preceding or following item, wherein the polymer film is connected to interconnected polymer filaments.

[0505] Clause 232. The method of any preceding or following clause, wherein the polymer film is bonded to interconnected polymer filaments.

[0506] Clause 233. The method of any preceding or following clause, wherein the molten polymer filaments are extruded into a medium interface (e.g., an air / water interface) defined by a first medium (e.g., air) and a second medium (e.g., water), such that at least a subset of the molten polymer filaments are deflected and / or bent (e.g., redirected) to intersect, intertwine, entangle, and / or bond while solidifying, such as with cooling water, to form the (e.g., nonwoven) web in the second medium (e.g., water).

[0507] Clause 234. The method of any preceding or following clause, further comprising removing the (e.g., nonwoven) network from the second medium (e.g., water) and drying the (e.g., nonwoven) network.

[0508] Clause 235: The method of any preceding or following clause, wherein the first medium is a gas (e.g., air) and the second medium is a liquid (e.g., water).

[0509] Item 236. The method of any preceding or following item, wherein the first medium is air and the second medium is water.

[0510] Clause 237. The method of any preceding or following clause, wherein the plurality of openings (e.g., a first subset) are arranged with a first opening density and the one or more additional openings (e.g., a second subset) are arranged with a second opening density different from the first opening density.

[0511] Clause 238. The method of any preceding or following clause, wherein the plurality of openings defines a first average diameter and one or more additional openings define a second average diameter different from the first average diameter.

[0512] Clause 239. The method of any preceding or following clause, wherein the first portion of the (e.g., nonwoven) mesh has a first stiffness and the second portion of the (e.g., nonwoven) mesh has a second stiffness that is different from the first stiffness.

[0513] Clause 240. The method of any preceding or succeeding clause, wherein a first thermoplastic polymer is extruded through the orifices in the first region such that the first portion is a plastic braid base of interconnected polymer filaments and a second thermoplastic polymer is extruded through the one or more orifices in the second region such that the second portion is a first plastic braid bolster of interconnected polymer filaments attached to a plastic braid base, the second thermoplastic polymer being different from the first thermoplastic polymer.

[0514] Clause 241. The method of any preceding or following clause, further comprising extruding (e.g., extruding) the first thermoplastic polymer, the second thermoplastic polymer, or a third thermoplastic polymer (e.g., different from the first and / or second materials) through a third region of the die apparatus such that a third portion of the network is a second plastic network bolster.

[0515] Clause 242: The method of any preceding or following clause, wherein the plastic mesh base includes a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face, and the first plastic mesh bolster is attached to the plastic mesh base at the first edge.

[0516] Clause 243: The method of any preceding or following clause, wherein the second plastic mesh bolster is attached to the plastic mesh base at the second edge.

[0517] Clause 244: The method of any preceding or succeeding clause, wherein the first plurality of openings (e.g., a first subset) in the first region of the die plate defines a first open space per unit area and the one or more additional openings in the second region define a second open space per unit area in the second region, the first open space per unit area being greater than the second open space per unit area.

[0518] Clause 245. The method of any preceding or following clause, further comprising heating a polymeric material to a molten state such that the molten polymeric filament and / or the additional molten polymeric member are formed as the molten polymeric material is received by and expelled through the die apparatus.

[0519] Clause 246. The method of any preceding or following clause, further comprising surrounding the molten polymer filaments with a heating device operable to apply heat to the molten polymer filaments.

[0520] Clause 247. The method of any preceding or following clause, further comprising introducing the molten polymer filaments and / or the additional molten polymer member into a cooling bath to form the network of interconnected polymer filaments.

[0521] Item 248. The method of any preceding or following item, wherein a second medium (e.g., water) is disposed in the cooling (e.g., water) bath.

[0522] 249. The method of any preceding or following claim, wherein the die apparatus includes a die plate.

[0523] Clause 250. The method of any preceding or following clause, wherein the die apparatus includes a template.

[0524] Item 251. The method of any preceding or following item, wherein cooling occurs after the molten polymer filaments leave the die plate.

[0525] Clause 252. The method of any of the preceding or following clauses, wherein the one or more additional openings include an opening sized to fit a periphery of the product, and the die apparatus maintains the molten polymer filaments within the periphery of the product.

[0526] Clause 253. The method of any preceding or following clause, wherein the number of openings per unit area in the first region is greater than the number of openings per unit area in the second region.

[0527] Clause 254. The method of any preceding or following clause, wherein the first plurality of openings comprises a larger diameter than the one or more additional openings.

[0528] Clause 255. The method of any preceding or following clause, further comprising shielding (e.g., covering) a portion of a die plate with a template including a predetermined contour such that the (nonwoven) web has a cross-section defined by the predetermined contour.

[0529] Clause 256. The method of any preceding or following clause, wherein the second region includes a location within the mesh that corresponds to a location of an occupant sensor.

[0530] Clause 257. The method of any preceding or following clause, wherein the second regions correspond to respective bolster regions of the cushion.

[0531] Clause 258. The method of any preceding or following clause, wherein the die apparatus includes a third region defining a second plurality of openings, the third region defining a third ratio of third closed area to third open area that is different from the first and / or second ratios.

[0532] Clause 259. The method of any preceding or following clause, wherein the third open area per unit area is less than the first and / or second open area per unit area.

[0533] Clause 260. The method of any preceding or following clause, further comprising heating an entire circumference of the molten polymer filament.

[0534] Item 261. The method of any preceding or following item, further comprising replacing the die assembly or a portion thereof with a second die assembly or a portion thereof.

[0535] Item 262. The method of any preceding or following item, wherein the die apparatus or portion thereof includes an exchangeable die plate or template.

[0536] Clause 263. The method of any preceding or following clause, wherein the plurality of openings form a dimensional or distribution gradient along the die assembly such that the network includes a hardness gradient.

[0537] Clause 264: The method of any preceding or following clause, wherein a third region of the die apparatus is configured to provide a third portion of the (e.g., nonwoven) mesh having a third stiffness that is higher than a first stiffness of the first portion of the (e.g., nonwoven) mesh, and a second stiffness of the second portion of the mesh.

[0538] Clause 265: The method of any preceding or following clause, wherein the second portion is disposed between the first portion and the third portion.

[0539] Clause 266. The method of any preceding or following clause, wherein the third portion has a hardness that is different from the second hardness and within 10% of the first hardness.

[0540] Clause 267: The method of any preceding or following clause, wherein the additional molten polymer material (e.g., a film) is extruded onto an outer surface of the network.

[0541] Clause 268. The method of any preceding or following clause, further comprising discharging the film onto an exterior surface of the mesh.

[0542] Clause 269. The method of any preceding or following clause, wherein the additional molten polymer material (e.g., a film) is extruded between at least two subsets of the interconnected polymer filaments.

[0543] Clause 270. The method of any preceding or following clause, further comprising discharging the film between at least two subsets of the interconnected polymer filaments.

[0544] Clause 271. The method of any preceding or following clause, further comprising forming an opening through the film.

[0545] Clause 272: The method of any preceding or following clause, wherein the one or more additional openings (e.g., a second subset) include a slit for discharging a film as the additional polymer member.

[0546] Clause 273. The method of any preceding or following clause, further comprising removing the dispensing assembly, or portion thereof, and installing a second dispensing assembly, or portion thereof.

[0547] Clause 274: The method of any preceding or following clause, further comprising discharging a different mesh through the second dispensing assembly, or a portion thereof.

[0548] Clause 275. The method of any preceding or following clause, further comprising assembling a seat comprising the (e.g., nonwoven) mesh.

[0549] Item 276. The method of any preceding or following item, wherein the film is an impermeable film.

[0550] Clause 277. The method of any preceding or following clause, further comprising attaching at least one of a seat trim, an actuator, and / or a heat transfer layer to the film.

[0551] Clause 278. The method of any preceding or following clause, wherein the heating apparatus includes a rectangular heating structure that surrounds the molten polymer filaments as they exit the die apparatus.

[0552] Clause 279. The method of any preceding or following clause, wherein the heating device is attached to a side of the die assembly.

[0553] Clause 280. The method of any preceding or following clause, wherein a heating device is attached to each side of the die assembly.

[0554] Item 281. The method of any preceding or following item, wherein the die arrangement is rectangular.

[0555] Clause 282. The method of any preceding or following clause, wherein the heating device controls the air temperature surrounding the molten polymer filaments to a temperature between 60°C and 140°C.

[0556] Clause 283. The method of any preceding or following clause, wherein the heating device is positioned at least 100 mm to 150 mm from the molten polymer filaments.

[0557] Clause 284. The method of any preceding or following clause, wherein the molten polymer filaments include an outer portion disposed on an outer edge of the die assembly and an inner portion disposed inward from the outer portion, and a heating device configured to heat the outer portion such that bonds between the molten polymer filaments in the outer portion are greater than bonds between the molten polymer filaments in the inner portion.

[0558] Clause 285. The method of any preceding or following clause, wherein a first polymeric material is discharged through the first region of the die apparatus and a second polymeric material is discharged through the second region of the die apparatus, the second polymeric material (e.g., polyethylene) being different from the first polymeric material (e.g., polypropylene, polystyrene, polycarbonate and / or polyvinyl chloride).

[0559] Clause 286. The method of any preceding or following clause, wherein the second polymeric material is introduced into the die assembly on an outer edge side of the die assembly and the first polymeric material is introduced into the die assembly inwardly from the second polymeric material such that the additional molten polymeric material at least partially surrounds the first polymeric filament.

[0560] Clause 287. The method of any preceding or following clause, further comprising extruding a third polymeric material, different from the first and / or second polymeric material, through the die apparatus.

[0561] Clause 288. The method of any preceding or following clause, wherein the third polymeric material is different from the first and second polymeric materials, and the first and second polymeric materials are different from each other.

[0562] Clause 289. The method of any preceding or following clause, wherein the first plurality of openings collectively have a larger area than the one or more additional openings.

[0563] Clause 290. The method of any preceding or following clause, wherein the first plurality of openings form a plurality of nozzles, the method further comprising closing the plurality of nozzles, or a subset thereof, outside the one or more additional openings.

[0564] Item 291. The method of any preceding or following item, further comprising cooling the die apparatus.

[0565] Item 292. The method of any preceding or following item, further comprising providing as the die apparatus a die having the one or more additional openings.

[0566] Clause 293. The method of any preceding or following clause, wherein the mold includes cooling passages for cooling the mesh.

[0567] Clause 294. The method of any preceding or following clause, further comprising placing the mold in a cooling fluid, the cooling fluid cooling the network.

[0568] Clause 295. The method of any preceding or following clause, wherein the mesh further comprises a concave contoured perimeter.

[0569] 296. An article such as a vehicle seat cushion formed by a method according to any of the preceding or following paragraphs.

[0570] 297. A vehicle interior part formed by a method according to any of the preceding or following headings.

[0571] Item 298. A system for manufacturing a non-foam vehicle seat cushion or the like, comprising: a molding assembly (e.g., die, template, funnel) including a die plate having a first region having a plurality of openings and a second region having one or more additional openings different from the plurality of openings; and an extruder that extrudes one or more polymeric materials through the molding assembly to form a mesh cushion body.

[0572] Clause 299. The system of any preceding or following clause, further comprising a template for blocking a portion of the opening, a funnel for forming molten polymer filaments extruded through the die plate into a unitary body and / or into a cooling bath, and a heating device for heating the molten polymer filaments and / or a conveyor assembly for transporting the unitary body through the cooling bath.

[0573] Clause 300: The system of any preceding or succeeding clause, wherein (i) the first region of the die plate defines a first closed portion and a first open space, and the second region defines a second closed portion and a second open space, the first closed portion being different from the second closed portion and / or the first open space being different from the second open space; (ii) the first region defines a perimeter of a shape of a final product; (iii) the one or more additional openings include a slit for discharging a polymer film; (iv) a first opening density of the first region is different from a second opening density of the second region; and / or (v) a dimension of the plurality of openings is different from a dimension of the one or more additional openings.

[0574] Clause 301. The system of any preceding clause, wherein the first region defines a first contour and the second region defines a second contour that is different from the first contour.

Claims

1. 1. A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to a molten state such that the polymeric material becomes a molten polymer; introducing the molten polymer into a die plate having a first region including a plurality of first holes extending therethrough and a second region including a plurality of second holes extending therethrough, the plurality of first holes collectively defining a first open space per unit area in the first region and the plurality of second holes collectively defining a second open space per unit area in the second region, the first open space per unit area being greater than the second open space per unit area; cooling the molten polymer after it exits the die plate; A method for manufacturing a vehicle interior part, comprising:

2. The method of claim 1 , wherein a number of the first holes per unit area in the first region is greater than a number of the second holes per unit area in the second region.

3. The method of claim 1 or 2, wherein the diameter of the first holes is greater than the diameter of the second holes.

4. 4. The method of claim 1, further comprising: producing a cushion blank by cooling the polymer after it exits the die plate, the method further comprising shielding a portion of the die plate with a template having a predetermined contour such that the cushion blank has a cross-section defined by the predetermined contour.

5. The method of claim 4 , wherein the second region includes a location in the cushion blank that corresponds to a location of an occupant sensor.

6. The method according to claim 4 or 5, wherein the die plate includes two of the first regions, each of which is disposed at a position corresponding to a respective bolster region of the cushion blank.

7. 7. The method of claim 6, wherein the die plate has a third region including a plurality of third holes therethrough, the plurality of third holes together defining a third open volume per unit area within the third region, the third open volume per unit area being smaller than the second open volume per unit area.

8. 8. A vehicle interior component formed by the method of any one of claims 1 to 7.

9. 1. A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to a molten state such that the polymeric material becomes a molten polymer; introducing the molten polymer into a die plate including a first region having an open portion and a closed portion and a second region having an open portion and a closed portion, wherein a ratio of the open portion of the first region to the first region is greater than a ratio of the open portion of the second region to the second region; cooling the molten polymer after it exits the die plate; A method for manufacturing a vehicle interior part, comprising:

10. 10. The method of claim 9, wherein the first region includes a plurality of first holes defining the open portion of the first region and the second region includes a plurality of second holes defining the open portion of the second region, and a number of the first holes per unit area of ​​the first region is greater than a number of the second holes per unit area of ​​the second region.

11. 11. The method of claim 9 or 10, wherein the first region includes a plurality of first holes defining the open portion of the first region and the second region includes a plurality of second holes defining the open portion of the second region, the first holes having a larger diameter than the second holes.

12. 12. The method of claim 9, wherein the vehicle interior part includes a cushion blank having a cross-section, the method further comprising shielding a portion of the die plate with a template having a contour that defines the cross-section of the cushion blank.

13. The method of claim 12 , wherein the die plate includes a plurality of the first regions, each positioned at a location corresponding to a respective bolster region of the cushion blank.

14. 14. The method of claim 12 or 13, wherein the second region includes a location in the cushion blank configured to receive an occupant sensor.

15. 15. The method of claim 9, wherein the die plate further comprises a third region having an open portion and a closed portion, and a ratio of the open portion of the second region to the second region is greater than a ratio of the open portion of the third region to the third region.

16. 1. A die plate apparatus usable for manufacturing vehicle interior parts, comprising: a plate including a first region including a plurality of first holes extending therethrough and a second region including a plurality of second holes extending therethrough, the plurality of first holes collectively defining a first opening in the first region and the plurality of second holes collectively defining a second opening in the second region, wherein a ratio of the first opening to the first region is greater than a ratio of the second opening to the second region; A die plate apparatus comprising:

17. 17. The die plate apparatus of claim 16, wherein a number of said first holes per unit area in said first region is greater than a number of said second holes per unit area in said second region.

18. 18. A die plate apparatus according to claim 16 or 17, wherein the diameter of the first hole is greater than the diameter of the second hole.

19. 19. The die plate apparatus of claim 16, further comprising a template configured to cover at least a portion of the first plurality of holes, at least a portion of the second plurality of holes, or at least a portion of the first plurality of holes and the second plurality of holes, the template having a predetermined contour defining a cross-section of a portion of the vehicle interior part.

20. 20. The die plate apparatus according to claim 16, wherein the vehicle interior part is a seat cushion, and the plate includes two of the first regions, each of which is disposed at a position corresponding to a respective bolster region of the seat cushion.

21. 1. A method of manufacturing a product, comprising: discharging molten thermoplastic resin through a tool having an opening sized to correspond to a periphery of the article, the tool generating a plurality of filaments through the opening while maintaining the plurality of filaments within the periphery of the article; bending the strands by providing resistance to flow of the strands, such that the bent strands intersect as a single nonwoven body in the shape of the entire circumference of the article; A method of manufacturing a product comprising:

22. 22. The method of claim 21, further comprising cooling the plurality of strands as a single nonwoven product.

23. Dispensing the molten thermoplastic resin from a plurality of nozzles, the combined area of ​​the plurality of nozzles being greater than the area of ​​the opening; closing a subset of the plurality of nozzles outside the area of ​​the opening; 22. The method of claim 21 , comprising:

24. The method of claim 21 further comprising providing a plate as the tool.

25. The method of claim 21 further comprising cooling the tool.

26. The method of claim 21 further comprising providing as said tool a die having said opening therein.

27. 27. The method of claim 26, further comprising providing a cooling passage through the mold for cooling the single nonwoven product.

28. 30. The method of claim 27, further comprising placing the mold in a cooling fluid that cools the single nonwoven product.

29. discharging molten thermoplastic resin through a tool having an opening sized to fit a periphery of the article, the tool producing a plurality of filaments through the opening while maintaining the plurality of filaments within the periphery of the article; providing resistance to the flow of the plurality of strands to cause the strands to bend, so that the bent strands cross as a single nonwoven fabric in a circumferential shape of the product; A product produced by a method comprising:

30. 30. The article of claim 29, wherein the article further comprises a single nonwoven cushion.

31. 30. The article of claim 29, wherein the article further comprises a concave contoured perimeter.

32. 1. A tool including a tool body having an opening therethrough, the through opening is sized to fit around the entire periphery of the cushion; the through opening is configured to receive molten thermoplastic resin as a plurality of discharged filaments; The through opening is configured to maintain the plurality of discharge strands within the perimeter of the cushion.

33. 33. The tool of claim 32, wherein the through opening is shaped as a seat cushion, the through opening being configured to form a unitary nonwoven cushion.

34. 33. The tool of claim 32, wherein the through openings are formed with a curvature, the through openings being configured to form a unitary nonwoven cushion having the curvature.

35. 33. The tool of claim 32, wherein the through opening is provided with a plurality of curvatures having a radius of at least 12 millimeters.

36. 33. The tool of claim 32, wherein the through opening is formed with a convex perimeter to form a concave surface in the cushion.

37. 1. A system for manufacturing a cushion, comprising: a dispenser of molten thermoplastic resin; 33. The tool of claim 32 oriented relative to the dispenser to receive the molten thermoplastic resin; Including, the system.

38. 38. The system of claim 37, further comprising a fluid chamber for receiving the molten thermoplastic resin to provide resistance to the flow of the discharged strands so as to bend and cross the strands into a single nonwoven body in the shape of the entire circumference of the cushion.

39. 40. The system of claim 38, wherein the tool is oriented within the fluid chamber for cooling the discharged strands as a single nonwoven cushion.

40. 40. The system of claim 39, wherein cooling passages are formed through the tool to cool the discharged strands as the single nonwoven cushion.

41. Discharging molten thermoplastic resin into a plurality of filaments and at least one film; providing resistance to a flow of the discharged filaments; Including, The method, wherein providing the resistance includes expanding the plurality of strands by crossing and bonding at least a subset of the plurality of strands to one another and uniting them with the at least one film.

42. 42. The method of claim 41, further comprising cooling the plurality of filaments and the at least one film as a single product.

43. 43. The method of claim 42, further comprising cooling the plurality of filaments and the at least one film with a fluid that provides resistance to flow of the plurality of filaments.

44. 44. The method of claim 43, further comprising cooling the plurality of filaments in a fluid chamber.

45. 45. The method of any one of claims 41 to 44, further comprising dispensing the at least one film onto an exterior surface of the unitary body.

46. 46. ​​The method of any one of claims 41 to 45, further comprising discharging the at least one film between at least two subsets of the plurality of filaments.

47. 47. The method of any one of claims 41 to 46, further comprising forming an opening through the at least one film.

48. The discharging step comprises: Discharging the plurality of strands through a plurality of holes in the tool; Discharging the at least one film through at least one slit in the tool; and 48. The method of any one of claims 41 to 47, further comprising:

49. removing the tool from the extruder; attaching a second tool to the extruder; passing the molten thermoplastic resin through the second tool and discharging it as a second plurality of filaments and a second film; providing resistance to a flow of the dispensed second plurality of filaments; Including, 49. The method of claim 48, wherein providing the resistance includes expanding the second plurality of threads by crossing at least a subset of the second plurality of threads with one another and forming the second film and a second unitary body different from the first unitary body.

50. 50. The method of any one of claims 41 to 49, further comprising assembling a seat with a cushion formed by the method.

51. 51. An article formed by the method of any one of claims 41 to 50.

52. Discharging molten thermoplastic resin into a plurality of filaments and at least one film; providing resistance to a flow of the discharged filaments; Including, An article formed by a process in which the providing of resistance includes expanding the plurality of strands by crossing at least a subset of the plurality of strands with one another and uniting them with the at least one film.

53. 53. The product formed by the method of claim 52, further comprising forming said at least one film on an exterior surface of said unitary body.

54. 54. An article formed by the method of claim 52 or 53, further comprising forming the at least one film between at least two subsets of the plurality of strands as an impermeable film.

55. 55. An article formed by the method of any one of claims 52-54, further comprising forming an opening through said at least one film.

56. 56. A seat assembly produced by a method comprising assembling a seat comprising a cushion formed by the method of any one of claims 52 to 55.

57. 57. A seat assembly manufactured by the method of claim 56, further comprising attaching at least one of a seat trim, an actuator, and / or a heat transfer layer to the at least one film.

58. an expanded network of a plurality of interconnected thermoplastic filaments; at least one thermoplastic film integrally bonded to at least a subset of the plurality of filaments as a unitary body; Products containing.

59. 60. The article of claim 58, wherein said at least one film is stretched onto an outer surface of said unitary body.

60. 60. The article of claim 58 or 59, wherein the at least one film is impermeable.

61. 61. The article of any one of claims 58-60, wherein the at least one film is stretched between at least two subsets of the plurality of filaments.

62. 62. The article of claim 58, wherein an opening extends through the at least one film.

63. 63. A seat assembly comprising as a seat cushion a product according to any one of claims 58 to 62.

64. 64. The seat assembly of claim 63, further comprising at least one of a seat trim, an actuator, and / or a heat transfer layer attached to the at least one film.

65. 1. A tool including a body, The body is provided with a plurality of openings formed therethrough and at least one slit formed therethrough, and the tool is configured to dispense molten thermoplastic resin through the plurality of openings and the at least one slit.

66. an extruder for molten thermoplastic resin; 66. The tool of claim 65 attached to the extruder; Including, A system configured to extrude the molten thermoplastic resin through the tool as a plurality of filaments and at least one film.

67. 1. A method for manufacturing a vehicle interior part, comprising: heating the polymeric material to a molten state such that the polymeric material becomes a molten polymer; introducing molten polymer into a die plate having a plurality of holes disposed therethrough and forcing the molten polymer through the plurality of holes to form a plurality of molten polymer filaments; surrounding the molten polymer filaments with a heating device operable to apply heat to the molten polymer filaments; introducing the molten polymer filaments into a tank and cooling the molten polymer filaments to form an interconnected filament structure; A method for manufacturing a vehicle interior part, comprising:

68. 68. The method of claim 67, wherein the heating device comprises a rectangular heating structure that surrounds the molten polymer filament as it emerges from the die plate.

69. 70. The method of claim 67 or 68, wherein the die plate includes a plurality of sides, and the heating device is attached to each of the plurality of sides of the die plate.

70. 70. The method of any one of claims 67 to 69, wherein the heating device is configured to control the ambient temperature around the molten polymer filaments to a temperature between 60°C and 140°C.

71. 71. The method of any one of claims 67 to 70, wherein the heating device is positioned at least 100mm to 150mm from the molten polymer filaments.

72. 72. The method of any one of claims 67-71, wherein the molten polymer filaments include an outer portion disposed on a side of an outer edge of the die plate and an inner portion disposed inward from the outer portion, and the heating device is configured to heat the outer portion such that bonds between the molten polymer filaments in the outer portion are greater than bonds between the molten polymer filaments in the inner portion.

73. 73. The method of any one of claims 67-72, wherein the molten polymer is a first molten polymer comprising a first material, and the molten polymer filament is a first molten polymer filament, the method further comprising: introducing a second molten polymer comprising a second material into the die plate and passing the second molten polymer through the plurality of holes in the die plate to form a plurality of second molten polymer filaments.

74. 74. The method of claim 73, wherein the first molten polymer is introduced into the die plate on an outer edge side of the die plate and the second molten polymer is introduced into the die plate inward from the first molten polymer such that the first molten polymer filaments at least partially surround the second molten polymer filaments.

75. 75. A vehicle interior component formed by the method of any one of claims 67 to 74.

76. 1. A method for manufacturing a vehicle interior part, comprising: heating a first polymeric material to a molten state to produce a first molten polymer; extruding the first molten polymer to form a plurality of first molten polymer filaments; heating an entire circumference of the first molten polymer filament; cooling the first molten polymer filaments in a fluid bath to form an interconnected filament structure; A method for manufacturing a vehicle interior part, comprising:

77. 77. The method of claim 76, wherein the first molten polymer comprises a first material, the method further comprising extruding a second molten polymer comprising a second material to form a plurality of second molten polymer filaments.

78. 78. The method of claim 77, wherein the first molten polymer and the second molten polymer are extruded such that the first molten polymer filament at least partially surrounds the second molten polymer filament.

79. 79. The method of any one of claims 76-78, wherein heating an entire circumference of the first molten polymer filament comprises heating the first molten polymer filament on four sides of the first molten polymer filament.

80. 80. The method of any one of claims 76-79, wherein heating the entire circumference of the first molten polymer filament comprises heating the first molten polymer filament to a temperature of from 60°C to 140°C.

81. 81. The method of any one of claims 76-80, further comprising heating an entire circumference of the first molten polymer filaments such that bonds between the first molten polymer filaments are greater than bonds between the second molten polymer filaments.

82. 82. A vehicle interior component formed by the method of any one of claims 76-81.

83. 1. A method for manufacturing a vehicle interior part, comprising: heating a polymeric material to form a molten polymer; forming a plurality of molten polymer filaments from the molten polymer by extruding the molten polymer through a die plate; heating the entire circumference of the molten polymer filament with a heating device; cooling the molten polymer filaments in a fluid bath to form an interconnected filament structure; A method for manufacturing a vehicle interior part, comprising:

84. 84. The method of claim 83, wherein the heating device is attached to the die plate.

85. 85. The method of claim 83 or 84, wherein the molten polymer is a first molten polymer comprising a first material, and the molten polymer filaments are first molten polymer filaments, the method further comprising introducing a second molten polymer comprising a second material into the die plate and passing the second molten polymer through the die plate to form a plurality of second molten polymer filaments.

86. 86. The method of claim 85, wherein the first molten polymer is introduced into the die plate on an outer edge side of the die plate and the second molten polymer is introduced into the die plate inward from the first molten polymer such that the second molten polymer filaments at least partially surround the first molten polymer filaments.

87. A vehicle seat cushion part, a plastic mesh base including a first plurality of three-dimensional filament loops comprised of a first thermoplastic polymer, the plastic mesh base having a first side edge, a second side edge, a leading edge, a trailing edge, a first surface, and a second surface; a first bolster including a second plurality of three-dimensional filament loops composed of a second thermoplastic polymer different from the first thermoplastic polymer, the first bolster attached to the plastic netting base at the first side edge; a second bolster attached to the plastic mesh base at the second side edge; A vehicle seat cushion part comprising:

88. 88. The vehicle seat cushion component of claim 87, wherein the second bolster includes a third plurality of three-dimensional filament annuli comprised of the second thermoplastic polymer.

89. 88. The vehicle seat cushion component of claim 87, wherein the second bolster includes a third plurality of three-dimensional filament annuli composed of a third thermoplastic polymer different from the first thermoplastic polymer.

90. 88. The vehicle seat cushion component of claim 87, wherein the second bolster includes a third plurality of three-dimensional filament annuli composed of a third thermoplastic polymer different from the first and second thermoplastic polymers.

91. 88. The vehicle seat cushion component of claim 87, wherein the second bolster includes a third plurality of three-dimensional filament annuli composed of a third thermoplastic polymer different from the first thermoplastic polymer.

92. 92. The vehicle seat cushion component of any one of claims 87-91, further comprising a third bolster including a fourth plurality of three-dimensional filament annuli comprised of a fourth thermoplastic polymer different from the first thermoplastic polymer.

93. 93. The vehicle seat cushion component of any one of claims 87-92, wherein the plurality of three-dimensional filament annuli includes a plurality of fusion connections where two annuli are attached to one another.

94. 94. The vehicle seat cushion component of any one of claims 87-93, wherein at least a subset of the annuli within the plurality of three-dimensional filament annuli are not parallel or aligned with one another.

95. 95. The vehicle seat cushion component of any one of claims 87-94, wherein the annuli within the plurality of three-dimensional filament annuli are randomly oriented.

96. 96. The vehicle seat cushion component of any one of claims 87 to 95, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

97. The vehicle seat cushion part according to any one of claims 87 to 96, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

98. 98. The vehicle seat cushion component of any one of claims 87 to 97, wherein the thermoplastic polymer comprises a first linear low density polyethylene.

99. 98. The vehicle seat cushion component of any one of claims 87 to 97, wherein the thermoplastic polymer comprises a second linear low density polyethylene different from the first linear low density polyethylene.

100. 100. A seating assembly comprising a frame and a cushion according to any one of claims 87 to 99 supported by the frame.

101. 1. A tool including a die, A tool, wherein the die defines a series of openings arranged to extrude material for a thread-like mesh material member for a cushion as described in any one of claims 87 to 99, the series of openings arranged to define an outer periphery of the member to define the plastic mesh base, the first bolster and the second bolster.

102. 102. The tool of claim 101, wherein the series of openings is further configured such that the perimeter defines the bolster.

103. extruding a first thermoplastic polymer to form a plastic network base having a first side edge, a second side edge, a leading edge, a trailing edge, a first surface, and a second surface, the plastic network base including a first plurality of three-dimensional filament loops; extruding a second thermoplastic polymer different from the first thermoplastic polymer to form a first bolster attached to the plastic netting base at the first side edge and including a second plurality of three-dimensional filament loops; extruding material to form a second bolster attached to the plastic mesh base at the second side end; The method includes:

104. 104. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of the second thermoplastic polymer.

105. 104. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

106. 104. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a third thermoplastic polymer different from the first and second thermoplastic polymers.

107. 104. The method of claim 103, wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops being comprised of a third thermoplastic polymer different from the first thermoplastic polymer.

108. 108. The method of any one of claims 103-107, further comprising a third bolster, the third bolster comprising a fourth plurality of three-dimensional filament loops, the fourth plurality of three-dimensional filament loops being comprised of a fourth thermoplastic polymer different from the first thermoplastic polymer.

109. 1. A non-foam seat cushion comprising:

1. A non-foam seat cushion comprising a plurality of entangled polymer strands, the plurality of entangled polymer strands having a first group of entangled polymer strands having a first hardness and a second group of entangled polymer strands having a second hardness different from the first hardness, the first group of entangled polymer strands and the second group of entangled polymer strands being connected.

110. 110. The non-foam seat cushion of claim 109, wherein the first group of entangled polymer strands has a first average diameter and the second group of entangled polymer strands has a second average diameter different from the first average diameter.

111. 111. The non-foam seat cushion of claim 109 or 110, wherein the first set of entangled polymer strands has a first bulk density and the second set of entangled polymer strands has a second bulk density different from the first density.

112. 112. The non-foam seat cushion of any one of claims 109 to 111, wherein the first hardness is less than the second hardness, the first hardness being 5 kPa or less.

113. 113. A non-foam seat cushion as claimed in any one of claims 109 to 112, wherein the second hardness is at least 5 kPa.

114. 114. The non-foam seat cushion of any one of claims 109-113, further comprising a third entangled polymer strand group from the plurality of entangled polymer strands having a third hardness, the second entangled polymer strand group being disposed between the first entangled polymer strand group and a third entangled polymer strand group, the first hardness being less than the second hardness and the third hardness being greater than the second hardness.

115. 115. The non-foam seat cushion of any one of claims 109-114, wherein the plurality of intertwined polymeric threads have a hardness gradient from a first region of the cushion to a second region of the cushion.

116. 116. A vehicle seat assembly including a seat frame supporting a non-foam cushion according to any one of claims 109 to 115.

117. A breaker plate, 1. A breaker plate comprising a solid body defining a plurality of orifices, the plurality of orifices comprising a first group of orifices and a second group of orifices, the first group of orifices being present at a first orifice density and having a first average diameter, the second group of orifices being present at a second orifice density and having a second average diameter, the first orifice density being different from the second orifice density, and / or the first average diameter being different from the second average diameter.

118. 118. The breaker plate of claim 117, wherein the first orifice density is different from the second orifice density.

119. 119. The breaker plate of claim 117 or 118, wherein the first average diameter is different from the second average diameter.

120. 120. The breaker plate of claim 117, 118 or 119, wherein the first orifice density is less than or equal to 11.5 orifices per square inch.

121. 121. The breaker plate of any one of claims 117 to 120, wherein the first average diameter and the second average diameter differ by at least 0.

4.

122. The first orifice density and the second orifice density are at least 3.0 kg / m ３ 122. The breaker plate of any one of claims 117 to 121, differing by only one factor.

123. 1. A system for dispensing a polymer resin, comprising: An extruder comprising the breaker plate of any one of claims 117 to 122 disposed therein; A system for extruding a polymer resin, wherein the extruder is configured to, during operation, extrude strands of the polymer resin through the plurality of orifices.

124. 1. A method for manufacturing a seat pad, comprising the steps of: discharging a molten polymer resin through a die defining a plurality of orifices to discharge a plurality of polymer strands at a media interface defined by a first medium and a second medium, thereby deflecting, entangling and curing at least a portion of the polymer strands to form a non-foam cushion within the second medium; removing the non-foam cushion from the second medium; drying the non-foam cushion; Including, The method of manufacturing a seating pad, wherein the plurality of orifices includes (i) a first group of orifices arranged at a first density and defining a first average diameter, and (ii) a second group of orifices arranged at a second density and defining a second average diameter, wherein the first density is different from the second density and / or the first average diameter is different from the second average diameter, and the non-foam cushion has a first region having a first hardness and a second region having a second hardness different from the first hardness.

125. 125. The method of claim 124, wherein the plurality of orifices are defined by a replaceable breaker plate.

126. 126. The method of claim 124 or 125, wherein the plurality of orifices are arranged to form a size and / or distribution gradient such that the non-foam cushion has a hardness gradient.

127. 127. The method of claim 124, 125 or 126, wherein the plurality of orifices includes a third group of orifices such that the non-foam cushion has a third region having a third hardness greater than the second hardness which is greater than the first hardness, the second region being disposed between the first region and the third region.

128. 128. The method of any one of claims 124 to 127, wherein the plurality of orifices includes a third group of orifices such that the non-foam cushion has a third region having a third hardness different from the second hardness and within 10% of the first hardness, the second region being disposed between the first region and the third region.

129. A cushion, a mesh including a plurality of interconnected polymer filaments; (i) the plurality of interconnected polymer filaments includes a first polymer filament subset and a second polymer filament subset different from the first polymer filament subset; and / or (ii) at least a portion of the interconnected polymer filaments are bonded to a polymer film. cushion.

130. 189. The cushion of any one of claims 129 or 131-188, wherein the first and second subsets are interconnected.

131. 132-188. The cushion of any one of claims 129, 130, or 132-188, wherein (a) the first subset has a first hardness and the second subset has a second hardness different from the first hardness; (b) the first subset has a first density and the second subset has a second density different from the first density; (c) the first subset has a first filament size and the second subset has a second filament size; and / or (d) the first subset is formed from a first polymeric material and the second subset is formed from a second polymeric material different from the first polymeric material.

132. 189. The cushion of any one of claims 129-131 or 133-188, wherein the first dimension is a first average diameter and the second dimension is a second average diameter.

133. 189. The cushion of any one of claims 129-132 or 134-188, wherein the mesh has a contoured shape.

134. 189. The cushion of any one of claims 129-133 or 135-188, wherein the firmness is a bulk firmness.

135. 189. The cushion of any one of claims 129-134 or 136-188, wherein the cushion is non-foamed.

136. 189. The cushion of any one of claims 129-135 or 137-188, wherein the portion of the interconnected polymer filaments are integrally bonded to a polymer film.

137. 189. The cushion of any one of claims 129-136 or 138-188, wherein the interconnected polymer filaments and the polymer film are made of the same polymer material.

138. 189. The cushion of any one of claims 129-137 or 139-188, wherein the film forms a skin along the mesh.

139. 189. The cushion of any one of claims 129-138 or 140-188, wherein the mesh is a nonwoven fabric.

140. 189. The cushion of any one of claims 129-139 or 141-188, wherein the mesh includes a base portion and an additional bolster portion.

141. 189. The cushion of any one of claims 129-140 or 142-188, wherein the first subset forms the base portion and the second subset forms the additional bolster portion.

142. 142. The cushion of claim 140 or 141, wherein the base portion defines a first contour and the additional portion defines a second contour that is different from the first contour.

143. 143. The cushion of any one of claims 140 to 142, wherein the additional bolster portion comprises a first bolster.

144. 144. The cushion of claim 143, wherein the first bolster is attached to the base portion at a first edge of the base portion.

145. 145. The cushion of claim 143 or 144, wherein the first bolster comprises the second polymer filament subset.

146. 146. The cushion of claim 145, wherein the first polymer filament subset comprises a first polymer material and the second polymer filament subset comprises a second polymer material different from the first polymer material.

147. 147. The cushion of any one of claims 143 to 146, wherein the additional bolster portion comprises a second bolster.

148. 148. The cushion of claim 147, wherein the second bolster is attached to the base portion at a second edge of the base portion.

149. 149. The cushion of claim 147 or 148, wherein the second bolster opposes the first bolster.

150. 147. The cushion of claim 146, wherein the second bolster includes a third polymer filament subset of the plurality of interconnected polymer filaments, the third polymer filament subset being different from the first polymer filament subset and / or the second polymer filament subset.

151. 151. The cushion of claim 150, wherein the third polymer filament subset comprises a third polymer material different from the first polymer material and / or the second polymer material.

152. 152. The cushion of any one of claims 147 to 151, wherein the additional bolster portion includes a third bolster.

153. 153. The cushion of claim 152, wherein the third bolster is attached to the base portion at a third edge of the base portion.

154. 154. The cushion of claim 153, wherein the third edge is a trailing edge of the base portion.

155. 155. The cushion of any one of claims 152-154, wherein the third bolster comprises a fourth polymer filament subset different from the first, second and / or third polymer filament subsets.

156. 156. The cushion of claim 155, wherein the fourth polymer filament subset comprises a fourth polymer material different from the first, second and / or third polymer material.

157. 157. The cushion of any one of claims 152-156, wherein the additional bolster portion includes a fourth bolster.

158. 158. The cushion of claim 157, wherein the fourth bolster is attached to the base portion at a fourth edge.

159. 156. The cushion of any one of claims 157 to 155, wherein the fourth bolster is opposed to the third bolster.

160. 160. The cushion of claim 158 or 159, wherein the fourth edge is a front edge of the base portion.

161. 161. The cushion of any one of claims 157-160, wherein the fourth bolster comprises a fifth polymer filament subset different from the first, second, third and / or fourth polymer filament subsets.

162. 162. The cushion of claim 161, wherein the fifth polymer filament subset comprises a fifth polymer material different from the first, the second, the third and / or the fourth polymer material.

163. 189. The cushion of any one of claims 129-162 or 164-188, wherein the plurality of interconnected polymeric filaments comprises a thermoplastic polymer.

164. 189. The cushion of any one of claims 131-163 or 165-188, wherein the density is bulk density.

165. 189. The cushion of any one of claims 129-164 or 166-188, wherein the first hardness is less than or equal to 5 kPa.

166. 189. The cushion of any one of claims 129-165 or 167-188, wherein the first hardness is less than the second hardness.

167. 189. The cushion of any one of claims 129-166 or 168-188, wherein the second hardness is at least 5 kPa.

168. 189. The cushion of any one of claims 129-167 or 169-188, wherein the plurality of interconnected polymer filaments includes a third polymer filament subset different from the first polymer filament subset and different from the second polymer filament subset.

169. 169. The cushion of claim 168, wherein the third subset has a different hardness than the first and second subsets.

170. 170. The cushion of any one of claims 168 or 169, wherein the second subset is disposed between the first and third subsets.

171. 171. The cushion of any one of claims 168-170, wherein the first subset has a first hardness and the second subset has a second hardness, the first hardness being less than the second hardness and the third hardness being greater than the second hardness.

172. 189. The cushion of any one of claims 129-171 or 173-188, wherein the plurality of interconnected polymer filaments have a hardness gradient from a first region to a second region.

173. 189. The cushion of any one of claims 129-172 or 174-188, wherein the polymeric film is arranged to form an outer surface of the mesh.

174. 189. The cushion of any one of claims 129-173 or 175-188, wherein the polymeric film is impermeable.

175. 189. The cushion of any one of claims 129-174 or 176-188, wherein the polymer film is disposed between a first polymer filament subset and a second polymer filament subset.

176. 189. The cushion of any one of claims 129-175 or 176-188, wherein the polymeric film defines an opening.

177. 189. The cushion of any one of claims 129-176 or 178-188, wherein the plurality of interconnected polymeric filaments includes a plurality of fusion connections where at least two filaments are bonded to one another.

178. 189. The cushion of any one of claims 129-177 or 179-188, wherein at least a portion of the polymer filaments are not parallel or aligned.

179. 189. The cushion of any one of claims 129-178 or 180-188, wherein polymer filaments in the plurality of interconnected polymer filaments are randomly oriented.

180. 189. The cushion of any one of claims 129-179 or 181-188, wherein the plurality of interconnected polymer filaments comprises a polymer selected from the group consisting of polyolefins, polyethylene, polystyrene, polyester, polyurethane, and polyamide.

181. 181. The cushion of claim 180, wherein the polyethylene is a low density polyethylene.

182. 182. The cushion of claim 180 or 181, wherein the polyethylene is linear.

183. 183. The cushion of any one of claims 180-182, wherein the plurality of interconnected polymer filaments comprises an additional polyethylene different from the first polyethylene.

184. 184. The cushion of any one of claims 129 to 183, wherein the cushion is a seat cushion.

185. 185. A seating assembly including a frame supporting a cushion as claimed in any one of claims 129 to 184.

186. 186. The seat assembly of claim 185, wherein the seat assembly is a vehicle seat assembly.

187. 187. A seat assembly as described in claim 185 or 186, further comprising a seat trim, an actuator and / or a heat transfer layer attached to the polymer film.

188. 188. A vehicle comprising a floor panel and a seat assembly as claimed in any one of claims 185 to 187 attached to the floor panel.

189. 1. A die tool comprising:

11. A die tool comprising: a body defining a first portion defining a first plurality of orifices to define a first open space and a first closed portion; and a second portion defining one or more orifices to define a second open space and a second closed portion, wherein: (i) the first open space and the first closed portion are different from the second open space and the second closed portion; (ii) the orifices define a shape of a final product having a first contour and a second contour that is different from the first contour; (iii) the one or more orifices include an elongated orifice that defines a polymer film; and / or (iv) the first plurality of orifices are different from the one or more orifices.

190. 221. The die tool of any one of claims 189 or 191-220, wherein the first portion has a different orifice density than the second portion.

191. 221. The die tool of any one of claims 189 or 192-220, wherein the first plurality of orifices are a different size than the one or more orifices.

192. 221. The die tool of any one of claims 189-191 or 193-220, wherein the first plurality of orifices in the first portion have a different average diameter than the one or more orifices in the second portion.

193. 221. The die tool of any one of claims 189-192 or 194-220, wherein the one or more orifices form at least one slit through the body.

194. 221. The die tool of any one of claims 189-193 or 195-220, wherein the orifice of the die tool is configured to eject molten thermoplastic resin.

195. 221. The die tool of any one of claims 189-194 or 196-220, wherein the one or more orifices are positioned to define a perimeter of a cushion having first and second bolsters.

196. 221. The die tool of any one of claims 189-195 or 197-220, wherein the one or more orifices is a second plurality of orifices.

197. 221. The die tool of any one of claims 189-196 or 198-220, wherein the first portion defines a first area, the first open space defines a first open area, the second portion defines a second area, and the second open space defines a second open area, the first open area to the first area defining a greater ratio than the second open area to the second area.

198. 221. The die tool of any one of claims 189-197 or 199-220, wherein the one or more orifices include a through opening sized to fit a perimeter of the cushion.

199. 200. The die tool of claim 198, wherein the through openings are configured to receive molten thermoplastic resin and expel it as a plurality of molten filaments.

200. 200. The die tool of claim 198 or 199, wherein the through openings are configured to maintain the plurality of molten filaments.

201. 191. The die tool of claim 190, wherein the first orifice density is less than or equal to 8 orifices per square inch.

202. 202. The die tool of claim 189 or 201, wherein the second orifice density is at least 9 orifices per square inch.

203. 193. The die tool of claim 192, wherein the first average diameter and the second average diameter differ by at least 0.4 mm.

204. 221. The die tool of any one of claims 189-203 or 205-220, wherein the first portion has a greater number of orifices per unit area than the second portion has a greater number of orifices per unit area.

205. 221. The die tool of any one of claims 189-204 or 206-220, further comprising a template configured to cover at least a portion of the plurality of orifices and / or one or more orifices.

206. 206. The die tool of claim 205, wherein the template has a predetermined contour that defines a cross-section of a portion of a vehicle interior part.

207. 207. The die tool of claim 205 or 206, wherein the template has a predetermined contour that defines a cross-section of a portion of the cushion.

208. 208. The die tool of claim 207, wherein the first portions are positioned at locations corresponding to respective bolster portions of the seat cushion.

209. 201. The die tool of any one of claims 198 to 200, wherein the through opening is formed as a seat cushion.

210. 210. The die tool of any one of claims 198-200 or 209, wherein the through openings are configured to form a unitary nonwoven cushion.

211. 211. The die tool of any one of claims 198-200, 209 or 210, wherein the through openings are formed into a curved shape to form a unitary nonwoven cushion having a curvature.

212. 212. A die tool according to any one of claims 198-200 or 209-211, wherein the through opening has a plurality of curvatures with a radius of at least 12 mm.

213. 213. The die tool of any one of claims 198-200 or 209-212, wherein the through opening is formed with a convex perimeter to form a concave surface of the cushion.

214. 221. A dispensing system including a dispenser having a die tool as described in any one of claims 189-213 or 215-220, wherein during operation, the dispenser dispenses molten thermoplastic resin through the orifice of the die tool.

215. 215. The dispensing system of claim 214, wherein the dispenser is an extruder that extrudes the molten thermoplastic resin through the orifices of the die tool to form molten thermoplastic filaments.

216. 216. The discharge system of any one of claims 214 to 215, further comprising a fluid chamber for receiving the molten thermoplastic filaments and providing resistance to the flow of the molten thermoplastic filaments, causing the filaments to bend and cross as a single nonwoven body in the shape of the entire circumference of the cushion.

217. 217. The discharge system of any one of claims 214-216, wherein the die tool is aligned with the fluid chamber to cool the molten thermoplastic filaments as a single nonwoven cushion.

218. 218. The discharge system of any one of claims 214 to 217, wherein the die tool defines cooling passages formed therethrough for cooling the molten thermoplastic filaments as a single nonwoven cushion.

219. 219. A vehicle interior part comprising a plurality of interconnected polymeric filaments extruded through the die tool of any one of claims 189-218.

220. 220. A cushion comprising a plurality of interconnected polymer filaments extruded through a die tool according to any one of claims 189 to 219.

221. Discharging molten polymer resin through a die apparatus having a first region defining a first plurality of openings for discharging a molten polymer filament and a second region defining one or more additional openings for discharging an additional molten polymer member different from the molten polymer filament, the first region defining a first ratio of first closed area to first open area that is different from a second ratio of second closed area to second open area of ​​the second region; cooling the molten polymer filaments and the additional molten polymer member to form a network including interconnected polymer filaments, the network having a first portion different from a second portion; The method includes:

222. 306. The method of any one of claims 221 or 223-297, wherein the mesh is a non-foam cushion.

223. 30. The method of any one of claims 221, 222, or 224-297, wherein the mesh is a vehicle interior component.

224. 30. The method of any one of claims 221-223 or 225-297, wherein the additional molten polymer member is an additional polymer filament having a different shape, size, density and / or composition.

225. 298. The method of any one of claims 221-224 or 226-297, wherein the molten polymeric material is extruded through the die apparatus.

226. 306. The method of any one of claims 221-224 or 227-297, wherein the first plurality of openings or the one or more additional openings define a perimeter of a final product shape.

227. 227. The method of claim 226, wherein the final product is a seat cushion.

228. 228. The method of claim 226 or 227, wherein the end product is a vehicle interior part.

229. 298. The method of any one of claims 221-228 or 230-297, wherein the first plurality of openings defines a first contour that is different from a second contour defined by the one or more additional openings.

230. 30. The method of any one of claims 221-229 or 231-297, wherein the additional molten polymer member is a polymer film.

231. 231. The method of claim 230, wherein the polymer film is connected to interconnected polymer filaments.

232. 232. The method of claim 230 or 231, wherein the polymer film is bonded to interconnected polymer filaments.

233. 302. The method of any one of claims 221-232 or 234-297, wherein the molten polymer filaments are extruded into a medium interface defined by a first medium and a second medium, such that at least a subset of the molten polymer filaments are deflected and / or bent to cross, intertwine and / or bond as they solidify to form the network within the second medium.

234. 234. The method of claim 233, further comprising removing the network from the second medium and drying the network.

235. 235. The method of claim 233 or 234, wherein the first medium is a gas and the second medium is a liquid.

236. 236. The method of any one of claims 233 to 235, wherein the first medium is air and the second medium is water.

237. 302. The method of any one of claims 221-236 or 238-297, wherein the plurality of openings are arranged in a first opening density and the one or more additional openings are arranged in a second opening density different from the first opening density.

238. 30. The method of any one of claims 221-237 or 239-297, wherein the plurality of openings defines a first average diameter and the one or more additional openings define a second average diameter different from the first average diameter.

239. 298. The method of any one of claims 221-238 or 240-297, wherein the first portion of the mesh has a first hardness and the second portion of the mesh has a second hardness different from the first hardness.

240. 306. The method of any one of claims 221-239 or 241-297, wherein a first thermoplastic polymer is extruded through the orifices in the first region such that the first portion is a plastic mesh base of interconnected polymer filaments and a second thermoplastic polymer is extruded through the one or more orifices in the second region such that the second portion is a first plastic mesh bolster of interconnected polymer filaments attached to a plastic mesh base, the second thermoplastic polymer being different from the first thermoplastic polymer.

241. 241. The method of claim 240, further comprising extruding the first thermoplastic polymer, the second thermoplastic polymer or a third thermoplastic polymer through a third region of the die apparatus such that a third portion of the mesh is a second plastic mesh bolster.

242. 242. The method of claim 240 or 241, wherein the plastic mesh base includes a first side edge, a second side edge, a front edge, a rear edge, a first face and a second face, and the first plastic mesh bolster is attached to the plastic mesh base at the first edge.

243. 243. The method of claim 242, wherein the second plastic mesh bolster is attached to the plastic mesh base at the second edge.

244. 30. The method of any one of claims 221 to 243 or 245 to 297, wherein the first plurality of openings in the first region define a first open space per unit area and the one or more additional openings in the second region define a second open space per unit area in the second region, the first open space per unit area being greater than the second open space per unit area.

245. 30. The method of any one of claims 221-244 or 246-297, further comprising heating a polymeric material to a molten state such that the molten polymeric filament and / or the additional molten polymeric member are formed when the molten polymeric material is received by and extruded through the die apparatus.

246. 302. The method of any one of claims 221-245 or 247-297, further comprising surrounding the molten polymer filament with a heating device operable to apply heat to the molten polymer filament.

247. 298. The method of any one of claims 221-246 or 248-297, further comprising introducing the molten polymer filaments and / or the additional molten polymer member into a cooling bath to form the network of interconnected polymer filaments.

248. 237. The method of any one of claims 233 to 236, wherein the second medium is disposed in the cooling bath.

249. 298. The method of any one of claims 221-248 or 250-297, wherein the die apparatus comprises a die plate.

250. 302. The method of any one of claims 221-249 or 251-297, wherein the die apparatus comprises a template.

251. 302. The method of any one of claims 221-250 or 252-297, wherein cooling occurs after the molten polymer filaments leave the die plate.

252. 30. The method of any one of claims 221-251 or 253-297, wherein the one or more additional openings include an opening sized to fit a perimeter of the product, and the die apparatus maintains the molten polymer filament within the perimeter of the product.

253. 302. The method of any one of claims 221-252 or 254-297, wherein the number of openings per unit area in the first region is greater than the number of openings per unit area in the second region.

254. 302. The method of any one of claims 221-253 or 255-297, wherein the first plurality of openings comprises a larger diameter than the one or more additional openings.

255. 298. The method of any one of claims 221-254 or 256-297, further comprising shielding a portion of a die plate with a template including a predetermined contour such that the mesh has a cross-section defined by the predetermined contour.

256. 298. The method of any one of claims 221-255 or 257-297, wherein the second region includes a location within the mesh that corresponds to a location of an occupant sensor.

257. 306. The method of any one of claims 221-256 or 258-297, wherein the second regions correspond to respective bolster regions of a cushion.

258. 30. The method of any one of claims 221-257 or 259-297, wherein the die apparatus includes a third region defining a second plurality of openings, the third region defining a third ratio of third closed area to third open area that is different from the first and / or second ratios.

259. 259. The method of claim 258, wherein the third open area per unit area is smaller than the first and / or second open area per unit area.

260. 30. The method of any one of claims 221-259 or 261-297, further comprising heating an entire circumference of the molten polymer filament.

261. 302. The method of any one of claims 221-260 or 262-297, further comprising replacing the die apparatus, or a portion thereof, with a second die apparatus, or a portion thereof.

262. 302. The method of any one of claims 221-260 or 263-297, wherein the die apparatus or portion thereof comprises an interchangeable die plate or template.

263. 306. The method of any one of claims 221-262 or 264-297, wherein the plurality of openings form a dimensional or distribution gradient along the die arrangement such that the mesh includes a hardness gradient.

264. 259. The method of any one of claims 241 or 258, wherein the third region of the die apparatus is configured to provide a third portion of the mesh having a third hardness that is higher than a first hardness of the first portion of the mesh and a second hardness of the second portion of the mesh.

265. 265. The method of claim 264, wherein the second portion is disposed between the first portion and the third portion.

266. 266. The method of any one of claims 241, 258, or 264-265, wherein the third portion has a hardness that is different from the second hardness and within 10% of the first hardness.

267. 306. The method of any one of claims 221-266 or 268-297, wherein the additional molten polymer material is extruded onto an outer surface of the mesh.

268. 233. The method of any one of claims 230-232, further comprising discharging the film onto an outer surface of the mesh.

269. 306. The method of any one of claims 221-266 or 268-297, wherein the additional molten polymer member is extruded between at least two subsets of the interconnected polymer filaments.

270. 233. The method of any one of claims 230-232, further comprising discharging the film between at least two subsets of the interconnected polymer filaments.

271. 271. The method of any one of claims 230-232, 268 or 270, further comprising forming an opening through the film.

272. 30. The method of any one of claims 221-271 or 273-297, wherein the one or more additional openings include a slit for discharging a film as the additional polymer member.

273. 306. The method of any one of claims 221-272 or 274-297, further comprising removing the dispensing assembly, or portion thereof, and installing a second dispensing assembly, or portion thereof.

274. 274. The method of claim 273, further comprising discharging a different mesh through the second dispensing assembly or a portion thereof.

275. 277. The method of any one of claims 221-274 or 276, further comprising assembling a seat comprising the mesh.

276. 269. The method of any one of claims 230-232 or 268, wherein the film is an impermeable film.

277. 277. The method of any one of claims 230-232, 268 or 276, further comprising attaching at least one of a seat trim, an actuator and / or a heat transfer layer to the film.

278. 247. The method of claim 246, wherein the heating device includes a rectangular heating structure that surrounds the molten polymer filament as it exits the die apparatus.

279. 298. The method of any one of claims 221-278 or 281-297, wherein the heating device is attached to a side of the die assembly.

280. 298. The method of any one of claims 221-278 or 281-297, wherein a heating device is attached to each side of the die assembly.

281. 302. The method of any one of claims 221-280 or 282-297, wherein the die arrangement is rectangular.

282. 281. The method of any one of claims 246 or 278-280, wherein the heating device controls the air temperature surrounding the molten polymer filaments to a temperature of between 60°C and 140°C.

283. 282. The method of any one of claims 246, 278-280, or 282, wherein the heating device is located at least 100 mm to 150 mm from the molten polymer filaments.

284. 30. The method of any one of claims 221-283 or 285-297, wherein the molten polymer filaments include an outer portion disposed on a side of an outer edge of the die apparatus and an inner portion disposed inward from the outer portion, and a heating device configured to heat the outer portion such that bonds between the molten polymer filaments in the outer portion are greater than bonds between the molten polymer filaments in the inner portion.

285. 298. The method of any one of claims 221-284 or 286-297, wherein a first polymeric material is discharged through the first region of the die apparatus and a second polymeric material is discharged through the second region of the die apparatus, the second polymeric material being different from the first polymeric material.

286. 286. The method of claim 285, wherein the second polymeric material is introduced into the die apparatus on an outer edge side of the die apparatus and the first polymeric material is introduced into the die apparatus inward from the second polymeric material such that the additional molten polymeric member at least partially surrounds the first polymeric filament.

287. 302. The method of any one of claims 221-286 or 288-297, further comprising discharging a third polymeric material, different from the first and / or second polymeric material, through the die apparatus.

288. 288. The method of claim 287, wherein the third polymeric material is different from the first and second polymeric materials, and the first and second polymeric materials are different from each other.

289. 298. The method of any one of claims 221-289 or 290-297, wherein the first plurality of openings collectively have a larger area than the one or more additional openings.

290. 302. The method of any one of claims 221 to 289 or 291 to 297, wherein the first plurality of openings form a plurality of nozzles, the method further comprising closing the plurality of nozzles or a subset thereof outside the one or more additional openings.

291. 302. The method of any one of claims 221-290 or 292-297, further comprising cooling the die apparatus.

292. 306. The method of any one of claims 221-291 or 293-297, further comprising providing a mold having the one or more additional openings as the die apparatus.

293. 300. The method of claim 292, wherein the mold comprises cooling passages for cooling the mesh.

294. 294. The method of claim 292 or 293, further comprising placing the mold in a cooling fluid, the cooling fluid cooling the mesh.

295. 298. The method of any one of claims 221-294 or 296-297, wherein the mesh further comprises a perimeter of a concave contour.

296. 302. An article of manufacture formed by the method of any one of claims 221 through 295.

297. 302. A vehicle interior component formed by the method of any one of claims 221 through 296.

298. a forming assembly including a die plate having a first region having a plurality of openings and a second region having one or more additional openings different from the plurality of openings; an extruder for extruding one or more polymeric materials through said molding assembly to form a mesh cushion body; A system including:

299. 300. The system of claim 298, further comprising: a template for blocking a portion of the opening; a funnel for forming a molten polymer filament extruded through the die plate into a unitary body and / or for directing the molten polymer filament into a cooling tank; and a heating device for heating the molten polymer filament and / or a conveyor assembly for transporting the unitary body through the cooling tank.

300. 300. The system of claim 298 or 299, wherein (i) the first region of the die plate defines a first closed portion and a first open space, and the second region defines a second closed portion and a second open space, the first closed portion being different from the second closed portion and / or the first open space being different from the second open space, (ii) the first region defines a perimeter of a shape of a final product, (iii) the one or more additional openings include slits for discharging a polymer film, (iv) a first opening density of the first region is different from a second opening density of the second region, and / or (v) dimensions of the plurality of openings are different from dimensions of the one or more additional openings.

301. 301. The system of any one of claims 298 to 300, wherein the first region defines a first contour and the second region defines a second contour that is different from the first contour.

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