Retainer for a seat assembly and method of assembly

Abstract

A retainer is described that includes an elongate member attached to a trim cover and a plurality of anchors extending from the elongate member. Each of the anchors has a body having a first end attached to the elongate member and a second end opposite the first end, the second end terminating in a sharp tip. Each of the anchors has a plurality of barbs, each barb extending from the body in a direction away from the tip. For each of the plurality of anchors, a cushioning material is gripped between the body and each of the barbs when the anchor is inserted into the cushion. A method of assembling a seat assembly that includes providing the retainer is also described.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 366,676, filed on June 20, 2022, and Danish Patent Application No. PA202370028, filed on January 19, 2023, and the entire disclosures of both of those applications are incorporated herein by reference in their entirety.

[0002] The present disclosure relates to a retainer, a sheet assembly having the retainer, and a method of assembly.

Brief Description of the Drawings

[0003]

Figure 1

Figure 2A

Figure 2B

Figure 2C

Figure 3

Figure 4

Figure 5

Best Mode for Carrying Out the Invention

[0004] Next, refer to the embodiments in detail. Examples thereof are shown in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, features, and elements have not been described in detail so as not to obscure aspects of the embodiments unnecessarily.

[0005] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily drawn to an exact scale, and some features may be exaggerated or minimized in order to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather should be interpreted as a representative basis for one of ordinary skill in the art to variously employ the embodiments of the present disclosure.

[0006] "One or more" and / or "at least one" includes that a function is performed by one element, that a function is performed by two or more elements in a distributed manner, for example, that multiple functions are performed by one element, that multiple functions are performed by multiple elements, or any combination of the above.

[0007] Also, terms such as first, second, etc. are used herein in some instances to describe various elements, but it will be understood that these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact. The first contact and the second contact are both contacts, but they are not the same contact.

[0008] The terms used in the description of the various embodiments herein are for the purpose of describing particular embodiments only and are not intended to be limiting. When used in the description of the various embodiments and the appended claims, the singular forms (“a”, “an” and “the”) are intended to include the plural forms as well, unless the context clearly dictates otherwise. Also, the term “and / or” as used herein, when referring to the relevant listed items, is understood to mean any and all possible combinations of one or more of the associated listed items and is used to encompass them. Further, the terms “comprising” or “including” as used herein are understood to specify the presence of the stated features, steps, acts, elements and / or components, but do not preclude the presence or addition of one or more other features, steps, acts, elements, components, and / or groups thereof.

[0009] As used herein, the term “when” is optionally construed, depending on the context, to mean “when”, or “as soon as”, or “in response to a determination”, or “in response to a detection”. Similarly, the phrases “when determined” or “when [stated condition or event] is detected” are optionally construed, depending on the context, to mean “as soon as determined”, or “in response to a determination”, or “as soon as [stated condition or event] is detected”, or “in response to a detection of [stated condition or event]”.

[0010] Referring to FIG. 1, a perspective view of a non-limiting exemplary embodiment of a seat assembly 10 is shown. The seat assembly 10 can be configured to be used in a vehicle such as an automobile like a passenger car or a truck. The seat assembly 10 can include a seat back 12 and a seat bottom 14. The seat back 12 can be configured to support the back of a seat occupant. The seat bottom 14 can be configured to support a seat occupant. In a vehicle application, the seat bottom 14 can be attached to a support surface such as a vehicle floor.

[0011] The seat back 12 can be pivotable about an axis 16 relative to the seat bottom 14. For example, one or more reclining chair mechanisms, pivot pins, etc. can pivotally connect the seat back 12 to the seat bottom 14. Alternatively, the seat back 12 or a part thereof may not be pivotally connected to the seat bottom 14. For example, the seat back 12 may be pivotally attached to the vehicle body structure so as to be a part of some bench seat configurations.

[0012] The seat back 12 can include a headrest 20 that can be configured to support the head of a seat occupant. The headrest 20 can be disposed at the top of the seat back 12. The headrest 20 may be integral with the seat back 12 or may be a separate component that can be adjustably positioned relative to the top of the seat back 12.

[0013] The seat back 12 and the seat bottom 14 can each have at least one seat cushion 30. The seat back 12 and the seat bottom 14 can each also have a side bolster 32 and a central seating portion 34 of the cushion 30. As will be described in more detail later, one or more retainers can be used to secure a seat component 36 to the cushion 30.

[0014] The seat component 36 can be disposed to cover or on top of the cushion 30. The seat component 36 can have any suitable configuration and can be of any suitable type. For example, the seat component 36 can be a trim cover, trim cover material, or trim cover assembly that provides at least a portion of the visible outer surface of the seat assembly 10. The trim cover 36 can include a plurality of trim panels that can be assembled by any suitable method such as sewing. The trim panels can be made of any suitable single or plural materials such as fabric, leather, vinyl, or combinations thereof. The seat component 36 can also be or alternatively be a component that is hidden by or disposed under the trim cover and disposed on top of the cushion 30, such as a temperature regulating device like a heating pad or heating mat, an inflatable device for improving the comfort of the seat occupant like a lumbar support, or a ventilation material that promotes air flow for a ventilated seat or that provides a massage function.

[0015] The cushion 30 can be at least partially hidden by the seat component 36 and can be supported directly or indirectly by the support structure of the seat assembly 10 such as a frame, panel, support wire, etc. The cushion 30 includes a three-dimensional mesh structure formed of filaments 60 that are randomly looped and joined, and only a few examples of the filaments 60 are depicted in FIG. 4 by lines randomly drawn for simplicity. For example, the filaments 60 may be extruded filaments made of a polymer material such as a thermoplastic resin that is polyamide-based, polyester-based, polyimide-based, polyolefin-based, polypropylene-based, polystyrene-based, or a combination thereof. As one example, the filaments 60 may be made of linear low-density polyethylene (LLDPE). The extruded filaments 60 can be randomly looped, bent, or intertwined and joined together at the locations where one filament 60 contacts another filament 60, thereby obtaining a lightweight and breathable cushion having openings or voids between the filaments 60. A method of manufacturing an extruded filament mesh cushion is disclosed in U.S. Patent Application No. 17 / 555,875, filed on December 20, 2021, entitled "System and Method of Making a Mesh Cushion", a copy of which is attached as Appendix A. Thus, the cushion 30 does not have to be made of a foam such as urethane foam and may partially or completely replace a conventional urethane foam cushion. Alternatively, the cushion may be a conventional foam cushion such as a urethane foam cushion.

[0016] Figures 2A-2C are perspective views of non-limiting exemplary embodiments of the retainer 40 according to the present disclosure. As seen in Figures 2A-2C and with continued reference to Figure 1, the retainer 40 in each embodiment includes an elongate member 42 and a plurality of anchors 44. In that regard, the elongate member 42 includes a planar strip and each of the plurality of anchors 44 is planar. However, individually or in combination, the elongate member 42 and the anchors 44 may take any other suitable configuration, or any other suitable configuration may be imparted to the elongate member 42 and the anchors 44.

[0017] In the embodiments shown in Figures 2A-2C, the elongate member 42 and the plurality of anchors 44 are formed as a single piece, but alternatively may be individual components attached to each other. In that regard, the retainer 40 including the elongate member 42 and the anchors 44 can be formed by injection molding, extrusion, and stamping, or by stamping or cutting (e.g., laser cutting) from a sheet. The elongate member 42 is also configured or provided to be attached to the trim cover 36. In that regard, the elongate member 42 can be sewn or stitched to the trim cover 36, but other known attachment means or methods may alternatively be employed. The elongate member 42, together with the anchors 44, can also be cut to any length suitable or necessary for use in a particular application or environment in which the component 36 is secured to the cushion 30 as described herein.

[0018] Each of the plurality of anchors 44 extends from the elongate member 42. Each of the plurality of anchors 44 has a body 46 having a first end 48 attached to the elongate member 42 and a second end 50 opposite the first end 48. The second end 50 terminates in a pointed tip. Each of the plurality of anchors 44 has a plurality of barbs 52, and each barb 52 extends from the body 46 in a direction away from the tip of the second end 50 of the anchor 44. For each of the plurality of anchors 44, the material of the cushion 30 is gripped between the body 46 and each of the plurality of barbs 52 when the anchor 44 is inserted into the cushion 30 (see FIG. 4). In that regard, the pointed tip of the second end 50 of each anchor 44 can serve or function to pierce the material of the cushion 30.

[0019] It should be noted that the anchor 44 including the barb 52 shown in FIGS. 2A to 2C is merely exemplary, and generally, it may take any shape or any shape may be given to them. The anchor 44 shown in FIG. 2A is given a shape that can be described as an inverted "Christmas tree", and the anchor 44 shown in FIG. 2C is given a shape that can be described as a "ship's anchor". In that regard, FIG. 3 is a side view of a non-limiting exemplary embodiment of the retainer 40 according to the present disclosure. More specifically, a side view of a single anchor 44 having an inverted "Christmas tree" shape from the embodiment of the retainer 40 of FIG. 2A is shown.

[0020] In that regard, the size and shape of the individual anchors 44 extending from the elongate member 42 may be different. For example, the shapes of the anchors 44 extending from the elongate member 42 may alternately repeat an inverted "Christmas tree" and a "ship's anchor" as shown in FIGS. 2A and 2C, respectively. Further, although shown to be spaced at equal intervals along the length of the elongate member 42, the distance between adjacent anchors 44 may be different and may vary. Similarly, the number of anchors per unit length of the elongate member 42 (i.e., the density) may also vary.

[0021] It is also noted that generally, the anchor 44 can take on any size, or any size can be given to the anchor 44. In this regard, for an anchor 44 that terminates in a pointed tip having a sharp angle or acute angle and has a second end 50 with a smaller cross-sectional area (for a cross-section across the body 46 of the anchor 44 in a direction parallel to the elongate member 42), less force needs to be applied to insert the anchor 44 into the material of the cushion 30 than for an anchor 44 that terminates in a pointed tip having a larger angle and has a second end 50 with a larger cross-sectional area. Thus, generally, for the anchor 44 of the embodiment shown in FIG. 2C, more force needs to be applied to insert it into the cushion 30 than for the anchor 44 of the embodiments shown in FIGS. 2A and 2B.

[0022] It is further noted that the number of barbs 52 for each of the anchors 44 shown in FIGS. 2A - 2C is merely illustrative, and any number of barbs 52 may be provided. Further, the number of barbs 52 on both sides of the anchor 44 may be different, the barbs 52 on both sides of the anchor 44 do not need to be positioned directly opposite each other (i.e., mirror images), the barbs 52 along the body 46 do not need to be spaced at equal intervals from each other, each barb 52 may take on a different shape, or different shapes may be given to each barb. In this regard, the larger the size and / or the greater the number of barbs 52 of the anchor 44, the more effective the anchor 44 is at gripping the material of the cushion 30, and the higher the resistance of the anchor 44 to coming out of or retracting from the cushion 30. Thus, the anchors 44 of the embodiments shown in FIGS. 2A and 2C have a higher resistance to coming out of the cushion 30 than the anchor 44 of the embodiment shown in FIG. 2B.

[0023] However, it should be noted that the optimal size and shape of the anchor 44 including the return 52 may be determined by the properties of the material of the cushion 30. In this regard, as described above, in the case of the cushion 30 including a three-dimensional mesh structure formed by filaments 60 randomly looped and joined of one or more extruded polymer materials, depending on the manufacturing process, cushions 30 with larger or smaller cell structures may be obtained. As a result, the size and shape of one or more of the anchors 44 shown in FIGS. 2A - 2C, or an anchor 44 having a size or shape different from that shown, may be most suitable for the material of a particular cushion 30.

[0024] FIG. 4 is another side view of a non-limiting exemplary embodiment of the retainer 40 according to the present disclosure. As seen in FIG. 4, a single anchor 44 having an inverted "Christmas tree" shape from the embodiment of the retainer 40 of FIG. 2A is shown, and the retainer 40 is partially disposed within the material of the cushion 30. More specifically, the anchor 44 of the retainer is shown in phantom lines in a state of being inserted into the material of the cushion 30, and the elongate member 42 is located on the surface of the cushion 30. As described above, the elongate member 42 of the retainer 40 can first be sewn or stitched to the trim cover 36. Thereafter, the anchor 44 of the retainer 40 is inserted into the material of the cushion 30. In this way, the trim cover 36 is thereby attached to the cushion 30.

[0025] Accordingly, the retainer 40 of the present disclosure can replace any known mechanism, device, system, means or method for attaching the trim cover 36 to the cushion 30, such as a conventional polyurethane foam cushion, including clips, hog rings and wire fasteners configured to be attached to the trim cover 36 and cooperate with the bead-like Duon™ attachment mechanism of the cushion 30, and / or attachment mechanisms or fasteners formed or molded within the cushion 30. In this regard, it is noted that the retainer 40 of the present disclosure need not be formed or molded within the material of the cushion 30. The retainer 40 of the present disclosure also makes it easier and / or possible to attach the trim cover 36 to a cushion 30 that has no formed, created, or provided single or plural recesses, such as a cushion 30 having a three-dimensional mesh structure formed by randomly looped and joined filaments 60 of one or more extruded polymeric materials as described above. However, the retainer 40 of the present disclosure is also suitable for attaching the trim cover 36 to a cushion 30 that includes single or plural recesses such as elongated channels, holes, depressions or grooves provided, formed, or created therein to receive the plural anchors 44, and the single or plural recesses can be provided at any suitable location, for example, where the side bolster 32 contacts the central seating portion 34 of the cushion 30 (see FIG. 1).

[0026] In that regard, as seen in FIG. 4, the cushion 30 includes a three-dimensional mesh structure formed of filaments 60 that are randomly looped and joined, and only a few examples of the filaments 60 are depicted in the drawing by lines randomly drawn for simplicity. As described above, the second end 50 of the anchor 44 terminates in a pointed tip, and a plurality of barbs 52 extend from the body 46 in a direction away from the pointed tip of the anchor 44, and they can serve to pierce or be capable of functioning to pierce the material of the cushion 30. Similarly as described above, when the anchor 44 is inserted into the cushion 30, the material of the cushion 30 (i.e., the looped and joined filaments 60) is gripped between the body 46 and each of the plurality of barbs 52. Thus, the retainer 40 of the present disclosure provides a trim retainer designed to bite into the material of the cushion 30, such as strands or filaments of a non-foam mesh cushion or pad. The retainer 40 of the present disclosure also provides barbs or barb attachments that enable or facilitate the adhesion of the trim cover 36 to the cushion 30, such as strands or filaments of a non-foam mesh cushion or pad.

[0027] Next, referring to FIG. 5, an exemplary flowchart showing a non-limiting exemplary embodiment of method 70 according to the present disclosure is shown. As seen in FIG. 5 and continuing to refer to FIGS. 1-4, method 70 of assembling a sheet assembly includes providing a retainer 40 having an elongate member 42 and a plurality of anchors 44 extending from elongate member 42 (72), where each of the plurality of anchors 44 has a body 46 having a first end 48 attached to elongate member 42 and a second end 50 opposite first end 48, second end 50 terminating in a pointed tip, and each of the plurality of anchors 44 has a plurality of flanges 52, each flange 52 extending from body 46 in a direction away from the tip. The method further includes attaching elongate member 42 to trim cover 36 (74) and inserting the plurality of anchors 44 into cushion 30 (76), with the material of cushion 30 being gripped between the plurality of flanges 52 and body 46 for each of the plurality of anchors 44.

[0028] According to assembly method 70 of the present disclosure, inserting the plurality of anchors 44 into cushion 30 (76) can include piercing the material of cushion 30 at the tip of each anchor 44 (78). As described above, elongate member 42 can include a planar strip, and attaching elongate member 42 to trim cover 36 (74) can include sewing or stitching elongate member 42 to trim cover 36 (80).

[0029] Here also, according to method 70 of the present disclosure, the plurality of anchors 44 can be spaced along elongate member 42 such that the spacing between adjacent anchors 44 is equal, although alternative spacings of anchors 44 can be provided as described above. Similarly as described above, elongate member 42 and the plurality of anchors 44 can be an integral member or formed as an integral member.

[0030] The assembly method 70 of the present disclosure can further include preparing (82) a cushion 30 which is a three-dimensional mesh structure formed by filaments looped and joined as described above. As described above, such filaments can be extruded and formed as a three-dimensional mesh structure. Further, according to the assembly method 70 of the present disclosure, as described above, the attachment of the trim cover 36 to the cushion 30 without one or more recesses formed in the cushion, such as the cushion 30 having a three-dimensional mesh structure formed by filaments 60 randomly looped and joined of one or more extruded polymer materials, becomes easier and / or possible. However, the retainer 40 of the present disclosure is also suitable for attaching the trim cover 36 to the cushion 30 including one or more recesses provided, formed, or fabricated inside.

[0031] Item 1. According to one embodiment, the present disclosure provides a retainer including a long member attached to a trim cover and a plurality of anchors extending from the long member, each of the plurality of anchors having a main body having a first end attached to the long member and a second end opposite to the first end, the second end terminating at a sharp tip, each of the plurality of anchors having a plurality of barbs, each barb extending from the main body in a direction away from the tip. For each of the plurality of anchors, the material of the cushion is gripped between the main body and each of the plurality of barbs when the anchor is inserted into the cushion.

[0032] Item 2. In another embodiment, the present disclosure provides the retainer according to Item 1, wherein the long member includes a flat strip.

[0033] Item 3. In another embodiment, the present disclosure provides the retainer according to Item 1 or 2, wherein each of the plurality of anchors is planar.

[0034] Item 4. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 3, wherein the elongate member is sewn to the trim cover.

[0035] Item 5. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 4, wherein a plurality of anchors are spaced along the elongate member such that the distance between adjacent anchors is equal.

[0036] Item 6. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 5, wherein the elongate member and the plurality of anchors are formed as an integral member.

[0037] Item 7. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 6, wherein the retainer is formed by injection molding or by stamping or cutting from a sheet.

[0038] Item 8. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 7, which pierces the cushion material with a sharp tip.

[0039] Item 9. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 8, wherein the cushion material includes a mesh formed from filaments looped and joined together.

[0040] Item 10. In another embodiment, the present disclosure provides the retainer according to Item 9, wherein the filaments are extruded and formed as a three-dimensional structure.

[0041] Item 11. In another embodiment, the present disclosure provides the retainer according to any one of Items 1 to 10, wherein the cushion material has no recesses formed to receive a plurality of anchors.

[0042] Item 12. In another embodiment, the present disclosure provides a seat assembly comprising a cushion, a trim cover, and a retainer as described in any one of Items 1 to 11, the retainer attaching the trim cover to the cushion.

[0043] Item 13. According to one embodiment, the present disclosure provides a method of assembling a seat assembly, the method comprising providing a retainer having an elongate member and a plurality of anchors extending from the elongate member, each of the plurality of anchors having a body with a first end attached to the elongate member and a second end opposite the first end, the second end terminating in a pointed tip, each of the plurality of anchors having a plurality of barbs, each barb extending from the body in a direction away from the tip, attaching the elongate member to a trim cover, and inserting the plurality of anchors into a cushion, wherein for each of the plurality of anchors, the material of the cushion is gripped between the plurality of barbs and the body.

[0044] Item 14. In another embodiment, the present disclosure provides the method according to Item 13, wherein inserting the plurality of anchors into the cushion includes piercing the material of the cushion with the tip of each anchor.

[0045] Item 15. In another embodiment, the present disclosure provides the method according to Item 13 or 14, wherein the elongate member includes a planar strip, and attaching the elongate member to the trim cover includes sewing the elongate member to the trim cover.

[0046] Item 16. In another embodiment, the present disclosure provides the method according to any one of Items 13 to 15, wherein the plurality of anchors are spaced along the elongate member such that the distance between adjacent anchors is equal.

[0047] Item 17. In another embodiment, the present disclosure provides the method according to any one of Items 13 to 16, wherein the elongate member and the plurality of anchors are an integral member.

[0048] Item 18. In another embodiment, the present disclosure provides the method according to any one of Items 13 to 17, further including preparing a cushion that is a three-dimensional mesh structure formed of filaments looped and joined together.

[0049] Item 19. In another embodiment, the present disclosure provides the method according to Item 18, wherein the filaments are extruded and formed as a three-dimensional mesh structure.

[0050] Item 20. In another embodiment, the present disclosure provides the method according to any one of Items 13 to 19, wherein the material of the cushion has no recesses formed to receive a plurality of anchors.

[0051] Exemplary embodiments have been described above, but these embodiments are not intended to describe all possible forms according to the present disclosure. In this regard, the language used in this specification is for explanatory purposes rather than limiting, and it is understood that various changes may be made without departing from the spirit and scope of the present disclosure. Further, unless otherwise indicated clearly in the context, various features, elements, components, methods, procedures, steps, and / or functions of various embodiments to be implemented may be combined or utilized in any single or plural combinations to form further embodiments according to the present disclosure, and / or may be executed in any order other than those specifically described herein. Appendix A [Document Name] Specification [Title of the Invention] System and Method for Manufacturing a Mesh Cushion [Technical Field]

[0050] This relates to a system and method for manufacturing a mesh cushion such as a mesh cushion for a seat. [Background Art]

[0051] An apparatus for manufacturing a three-dimensional filament connection structure is disclosed in U.S. Patent No. 10,806,272. [Summary of the Invention]

[0052] In at least one embodiment, a method of manufacturing a mesh cushion is provided. The method can include extruding a material through a plurality of filament-forming openings of a die plate to form a plurality of filaments. The filaments can be deposited onto a first roller and a second roller. The first roller can be rotatable about a first axis and can define a first recess. The second roller can be rotatable about a second axis and can define a second recess. The first roller and the second roller are rotated to guide the filaments into the first recess and the second recess and through a gap located between the first roller and the second roller, whereby the filaments can be formed into a mesh cushion having a variable cross-sectional shape.

[0053] The first roller and the second roller can be spaced apart from the die plate and positioned below the die plate.

[0054] The filaments can be deposited while the first roller and the second roller are rotating.

[0055] The first recess and the second recess may not have mirror symmetry.

[0056] The first roller can include a first central portion and a first end plate. The first recess can extend from the first central portion. The first end plate can be rotatable about the first axis together with the first central portion. The first end plate can extend further from the first axis than the first central portion. The first end plate can overlap the second roller and guide the filaments into the gap between the first roller and the second roller.

[0057] The second roller can include a second central portion and second end plates. The second recess can extend from the second central portion. The second end plates can be rotatable about a second axis together with the second central portion. The second end plates can extend further from the second axis than the second central portion. The second end plates can overlap the first roller and guide the filament into the gap between the first roller and the second roller.

[0058] The first end plate of the first roller and the second end plate of the second roller can overlap each other and guide the filament into the gap.

[0059] At least a portion of the first roller and the second roller can be positioned above a funnel that defines a funnel opening through which the material can pass.

[0060] The filament extruded through the die plate can be provided to a chamber that is partially defined by a housing extending between the die plate and the funnel. The first roller and the second roller can be at least partially received within the chamber.

[0061] An environmental control subsystem can control the temperature and humidity of the air within the chamber to control the thickness of the filament. The environmental control subsystem can be attached to the housing. The environmental control subsystem can maintain the temperature of the air within the chamber within a predetermined temperature range. The predetermined temperature range can be up to 10°F lower than the melting temperature of the material.

[0062] A method of manufacturing a mesh cushion can include extruding a material through a plurality of filament-forming openings of a die plate to form a plurality of filaments. The filaments can be guided into a funnel to solidify and engage the filaments. The filaments can then be deposited into a mold. The mold can be at least partially immersed in a fluid to cool and cure the filaments into a mesh cushion.

[0063] The mold can be disposed on a conveyor. The conveyor can move or lower the mold into the fluid.

[0064] The mold can be partially received in the fluid when the filaments are deposited.

[0065] The filaments extruded through the die plate can be provided to a chamber that includes a housing and extends between the die plate and the funnel.

[0066] A method of manufacturing a mesh cushion can include providing a die set that includes a first die plate and a second die plate disposed adjacent to each other. The material can be extruded through a first set of filament-forming openings of the first die plate and through a second set of filament-forming openings of the second die plate to form a plurality of filaments. The relative position of the second die plate with respect to the first die plate can be changed such that the second die plate prevents the material from passing through some of the elements of the first set of filament-forming openings, thereby reducing the number of filaments formed by the die set. The filaments formed by the die set can be immersed in a fluid to cool and cure the filaments into a mesh cushion.

[0067] The second set of filament-forming openings can have fewer elements than the first set of filament-forming openings.

[0068] The second die plate can be movable between a first position and a second position. The second die plate can enable material to pass through some of the elements of the first set of filament-forming openings when the die plate is in the first position and when it is in the second position.

[0069] At least one element of the second set of filament-forming openings is larger than the elements of the first set of filament-forming openings, and can enable material to flow through the elements of the first set of filament-forming openings when the second die plate is in the first position and when it is in the second position.

[0070] Before dipping the filament, the filament can be guided into a funnel to harden and engage the filament.

[0071] A method of manufacturing a mesh cushion can include extruding material through a plurality of filament-forming openings of a die plate to form a plurality of filaments. The die plate can be coupled to a robotic manipulator configured to move the die plate along a plurality of axes. The filaments can be deposited within a mold. The mold can be at least partially immersed in a fluid to cool and cure the filaments, thereby forming the filaments as a mesh cushion. The robotic manipulator can move the die plate when depositing the filaments to vary the filament density of the mesh cushion.

[0072] The material can be extruded through the plurality of filament-forming openings at a substantially constant flow rate.

[0073] The robotic manipulator can move the die plate away from the mold to reduce the diameter of the filaments when the filaments reach and deposit within the mold.

[0074] The robot manipulator can move the die plate toward the mold and increase the diameter of the filament when the filament reaches and deposits into the mold.

[0075] The robot manipulator can repeatedly move the die plate toward and then away from the mold to change the filament density.

[0076] The robot manipulator can move the die plate at high speed in a horizontal plane to reduce the filament density and at low speed to increase the filament density. [Brief Description of the Drawings]

[0077] [Fig. 1] is a schematic diagram of an example of a system for manufacturing a mesh cushion. [Fig. 2] is a partial plan view of Fig. 1 as viewed from below the die plate and above the roller that can be provided in the system. [Fig. 3] is a schematic diagram of a second example of a system for manufacturing a mesh cushion. [Fig. 4] is a schematic diagram of a third example of a system for manufacturing a mesh cushion. [Fig. 5A] is a diagram showing an example of filaments of different sizes. [Fig. 5B] is a diagram showing an example of filaments of different sizes. [Fig. 6A] is a diagram of an example of a die plate that can be provided in any system associated with Figs. 1 - 4. [Fig. 6B] is a diagram of an example of a die plate that can be provided in any system associated with Figs. 1 - 4. [Fig. 7] is a side view showing stacked die plates. [Fig. 8A] is a plan view of the stacked die plates in the first position. [Fig. 8B] is a plan view of the stacked die plates in the second position. [Mode for Carrying Out the Invention]

[0078] Where appropriate, detailed embodiments of the present invention are disclosed herein, but it should be understood that the disclosed embodiments are merely illustrative of the invention, which can be embodied in various alternative forms. The drawings are not necessarily drawn to exact scale, and some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as a representative basis for teaching those skilled in the art how to variously employ the present invention.

[0079] In the following description, terms such as "front", "rear", "top", "bottom", "left", "right", etc., terms that modify absolute positions, or terms such as "above", "below", "upper side", "lower side", etc., terms that modify relative positions, or terms such as "horizontal", "vertical", etc., terms that modify directions, refer to the orientation of the drawings. Unless otherwise specified, the expressions "about", "substantially", and "on the order of" mean within 10%, preferably within 5%.

[0080] Referring to FIG. 1, an example of a system 10 for manufacturing a mesh cushion 12 is shown. This system can include an extrusion machine subsystem 20, an environmental control subsystem 22, a material handling subsystem 24, and a control subsystem 26.

[0081] The extrusion machine subsystem 20 can be configured to extrude a material 30 as a filament 32. In at least one configuration, the extrusion machine subsystem 20 can include a container 40, a feeder 42, a manifold 44, and an extrusion machine 46. The extrusion machine subsystem 20 can also include a first roller 50, a second roller 52, and a roller drive unit 54.

[0082] Container 40 can accommodate and store fragments of the material 30 to be extruded. For example, container 40 can be configured as a hopper that can hold beads, granules, flakes, pellets, or powder made from material 30. Material 30 can be a polymeric material such as polyester or polyethylene. Container 40 may be directly attached to feeder 42 or positioned at a location remote from feeder 42.

[0083] Feeder 42 can receive material 30 from container 40. Feeder 42 can gradually melt the material and transfer it to manifold 44. Feeder 42 can have any suitable configuration. For example, feeder 42 can include a barrel that can accommodate a rotatable screw. The rotation of the screw can force material 30 to move through the barrel, and the friction generated as the screw rotates can help heat material 30. A heating element such as a thermocouple can be disposed proximate to the barrel, and the heating element can provide thermal energy that can heat the barrel and material 30. Optionally, the heating elements can be arranged to provide a heating profile having a plurality of zones in which the temperature of material 30 gradually increases as material 30 progresses through the barrel. Cooling equipment can also be provided to help maintain the temperature below a predetermined value if excessive heat is generated. Material 30 can exit feeder 42 in a molten plastic state.

[0084] Manifold 44 can receive the molten material 30 from feeder 42 under pressure. Manifold 44 can direct material 30 from feeder 42 to extruder 46.

[0085] Extruder 46 can extrude material 30 as filament 32. Extruder 46 can have any suitable configuration. For example, extruder 46 can include one or more die plates 60, a housing 62, and a hopper 64.

[0086] One or more die plates 60 can be provided that can include a plurality of filament forming openings 70. The filament forming openings 70 can be spaced apart from each other and can be small through holes sized to create a back pressure within the manifold 44 and the barrel. The material 30 provided by the manifold 44 can pass through the filament forming openings 70 under pressure (i.e., be extruded from the die plate 60), thereby forming filaments 32. The filaments can be formed by each filament forming opening 70 through which the material 30 passes under pressure.

[0087] The housing 62 can receive and support the die plate 60. Additionally, the housing 62 can extend between the die plate 60 and the funnel 64. The housing 62 can cooperate with the die plate 60 and the funnel 64 to fully or partially define a chamber 80. The chamber 80 can be disposed below the die plate 60 and above the funnel 64. Thus, the filaments 32 formed by or extruded through the die plate 60 can be provided to the chamber 80. The chamber 80 can be a sealed area that is at least partially separated or isolated from the surrounding environment. In FIGS. 1, 3, and 4, the side of the housing 62 closest to the viewer from the illustrated perspective is omitted to better show the internal features of the housing 62. The environmental control subsystem 22 can serve to control the environment within the chamber 80, as will be discussed in more detail later.

[0088] The funnel 64, if provided, can be disposed proximate to the bottom of the housing 62. The funnel 64 can define a funnel opening 90 through which the material 30, or the mesh cushion 12 made from the material 30, can pass. The funnel opening 90 can have a width smaller than the filament forming opening 70 extends along the die plate 60, or can extend along a short distance. Thus, the funnel opening 90 can serve to solidify or compress the filaments 32 in one or more configurations. In at least one configuration, the funnel 64 can extend into the fluid provided by the material handling subsystem 24, which can serve to isolate the chamber 80 from the ambient air and the surrounding environment. In one or more configurations, it is also contemplated that the funnel 64 may be omitted. If the funnel 64 is omitted, it is also contemplated that the housing 62 can extend into the fluid within the material handling subsystem 24. In the configuration shown in FIG. 1, the funnel 64 passes between the first roller 50 and the second roller 52 and receives the material 30 formed by the first roller 50 and the second roller 52.

[0089] The first roller 50 can be positioned between the die plate 60 and the funnel 64. For example, the first roller 50 can be positioned below the die plate 60 and spaced from the die plate 60. At least a portion of the first roller 50 can be disposed above the funnel 64 and spaced from the funnel 64. Thus, the first roller 50 can be at least partially received within the chamber 80. The first roller 50 is rotatable about a first axis 100. In at least one configuration, as best shown in FIG. 2, the first roller 50 can have a first central portion 110, at least one recess 112, one or more end plates 114, or a combination thereof.

[0090] The first central portion 110 can extend around or surround the first axis 100. In at least one configuration, the first central portion 110 can be disposed at a constant or substantially constant radial distance from the first axis 100. The first central portion 110 can be positioned above the funnel 64.

[0091] At least one recess 112 can extend from the first central portion 110 toward the first axis 100. In the illustrated configuration, a single recess 112 is shown, but it is contemplated that a plurality of recesses may be provided. Additionally, the plurality of recesses may be spaced apart from each other.

[0092] One or more end plates 114 can be provided on the first roller 50. In the illustrated configuration, two end plates 114 are shown disposed adjacent to both ends of the first central portion 110. The end plates 114 can be rotatable about the first axis 100 together with the first central portion 110. Additionally, the end plates 114 can extend further from the first axis 100 than the first central portion 110. The end plates 114 can serve to contain the filament 32 so that the filament 32 does not roll off the end of the first roller 50 and can serve to guide the filament 32 into the gap 116 located between the first roller 50 and the second roller 52. The size and configuration of the gap 116 can vary as the first roller 50 and the second roller 52 rotate.

[0093] Referring to FIGS. 1 and 2, the second roller 52 can be generally aligned with the first roller 50. Thus, the second roller 52 can be positioned between the die plate 60 and the hopper 64, can be positioned below the die plate 60, and can be spaced apart from the die plate 60. At least a portion of the second roller 52 can be disposed above the hopper 64. Thus, the second roller 52 can be at least partially received within the chamber 80. The second roller 52 is rotatable about a second axis 100'. In at least one configuration, as best shown in FIG. 2, the second roller 52 can have a second central portion 110', at least one recess 112', one or more end plates 114', or a combination thereof.

[0094] The second central portion 110' can extend around or surround the second axis 100'. In at least one configuration, the second central portion 110' can be disposed at a constant or substantially constant radial distance from the second axis 100'. The second central portion 110' can be positioned above the hopper 64.

[0095] At least one recess 112' can extend from the second central portion 110' toward the second axis 100'. In the illustrated configuration, a single recess 112' is shown, but it is contemplated that multiple recesses may be provided and the recesses may be spaced apart from each other. In at least one configuration, the recesses 112' provided in the second roller 52 may not have mirror symmetry with corresponding recesses provided in the first roller 50, thereby forming a mesh cushion having opposing side surfaces with different configurations.

[0096] One or more end plates 114' can be provided on the second roller 52. In the illustrated configuration, two end plates 114' are shown disposed proximate to both ends of the second central portion 110'. The end plates 114' can be rotatable about the second axis 100' together with the second central portion 110'. In addition, the end plates 114' can extend further from the second axis 100' than the second central portion 110'. The end plates 114' can serve to accommodate the filament 32 so that the filament 32 does not roll off the ends of the second roller 52 and can serve to guide the filament 32 into the gap 116.

[0097] The end plate 114 provided on the first roller 50 can engage with an adjacent end plate 114' provided on the second roller 52, overlap with the end plate 114', and can serve to guide the filament 32 into the gap 116. In addition, the end plate can overlap a roller on which the end plate is not attached. For example, the end plate 114 provided on the first roller 50 can overlap the second roller 52 and can serve to guide the filament into the gap 116. In addition or alternatively, the end plate 114 provided on the first roller 50 can have an outer circumference or outer surface facing away from the first axis 100 and disposed closer to the second axis 100' than the second central portion 110' is disposed with respect to the second axis 100'. The end plate 114' provided on the second roller 52 can have an outer circumference or outer surface facing away from the second axis 100' and disposed closer to the first axis 100 than the first central portion 110 is disposed with respect to the first axis 100. The end plates 114, 114' may be received inside the funnel 64 or may be disposed outside the funnel 64. The outer circumference or outer surface of the end plates 114, 114' may or may not be positioned above the funnel 64.

[0098] The roller drive unit 54 can be configured to rotate the first roller 50 and the second roller 52. For example, the roller drive unit 54 can rotate the first roller 50 and the second roller 52 in opposite directions about their respective axes. In FIG. 1, as represented by the curved arrow lines, the first roller 50 can be rotated clockwise about the first axis 100 as viewed from the illustrated perspective, while the second roller 52 can be rotated counterclockwise about the second axis 100' as viewed from the illustrated perspective. In addition, the roller drive unit 54 can synchronize the rotations of the first roller 50 and the second roller 52 such that the recess 112 of the first roller 50 aligns with the recess 112' of the second roller 52 during each roller rotation, thereby enabling the both sides of the mesh cushion 12 to be formed to have a desired cross section at each point along its length. If the synchronization of the rollers is inappropriate, the positions of the recesses may shift, and the mesh cushion 12 may be inappropriately formed.

[0099] It should be noted that in various extrusion machine sub-assembly configurations such as the configurations shown in FIGS. 3 and 4, the first roller 50, the second roller 52, and the roller drive unit 54 may be omitted.

[0100] The filament 32 can be deposited onto the first roller 50 and the second roller 52 while the first roller 50 and the second roller 52 are rotating. By the rotation of the first roller 50 and the second roller 52, the filament 32 can be guided towards and through the gap 116, thereby solidifying the filament 32 and bringing each filament 32 into contact with one or more other filaments 32. The filaments 32 can bend or twist in an irregular manner, generally in a non-patterned or non-repeating fashion. The recesses 112, 112' can further form the filaments 32 as the undulating outer surfaces of the portions of the filaments 32 that contact the surfaces of the respective rollers that define the corresponding recesses 112, 112'. Thus, since the cross-sectional area of each roller varies depending on the presence and configuration of the corresponding recesses 112, 112', the first roller 50 and the second roller 52 can form the filaments 32 as a mesh cushion 12 having a variable cross-sectional shape.

[0101] Referring to FIG. 1, the environmental control subsystem 22 can control one or more attributes or characteristics of the air inside the chamber 80. For example, the environmental control subsystem 22 can control the temperature of the air in the chamber 80, the humidity of the air in the chamber 80, the flow of air in the chamber 80, the recirculation of air in the chamber 80, the exhaust of air from the chamber 80, or a combination thereof, to help control the thickness of the filaments 32. In at least one configuration, the environmental control subsystem 22 can include fans 120 and one or more temperature-changing devices.

[0102] In FIGS. 1, 3, and 4, two temperature changing devices 122, 124 are shown, but it is contemplated that a different number of temperature changing devices may be provided. The temperature changing device can have any suitable configuration. For example, the temperature changing device can be configured as a heat exchanger, a heating element, a cooling element, etc. As one example, the first temperature changing device 122 can be configured to heat air, while the second temperature changing device 124 can be configured to cool and / or dehumidify the air that is circulated by the fan 120 from the chamber 80 through the environmental control subsystem 22 and back to the chamber 80.

[0103] The environmental control subsystem 22 can be used to maintain the temperature of the air within the chamber 80 within a predetermined temperature range. The predetermined temperature range may be slightly lower than the melting temperature of the material 30. As an example, the predetermined temperature range may be 10°F or less lower than the melting temperature of the material 30. Similarly, the environmental control subsystem 22 can be used to maintain the humidity of the air within the chamber 80 within a predetermined humidity range.

[0104] The components of the environmental control subsystem 22, such as the fan 120 and the temperature changing devices 122, 124, etc., may be attached to the housing 62 or positioned remotely from the extruder subsystem 20 and fluidly connected to the chamber 80 by any suitable conduit such as a hose or duct.

[0105] The material handling subsystem 24 can receive the material 30 after the material 30 exits the extruder subsystem 20. The material handling subsystem 24 can be provided in various configurations. In the configuration shown in FIG. 1, the material handling subsystem 24 includes a tank 130 and a conveyor 132.

[0106] Tank 130 can receive the material 30 coming from the extrusion machine subsystem 20. In addition, tank 130 can contain a fluid 134 such as water. The fluid 134 can be provided in a liquid state and at a temperature significantly lower than the melting temperature of the material 30. Thus, the fluid 134 can cool and harden the filament 32 to form the mesh cushion 12. Thus, the fluid 134 can cool the filament 32 so that the filament 32 is no longer in a sticky molten state.

[0107] Conveyor 132 can convey the mesh cushion 12. In at least one configuration, conveyor 132 or a part thereof can be housed within tank 130 and can be at least partially immersed in the fluid 134. The length of the conveyor 132 disposed in the fluid 134 can be sufficient to provide adequate cooling and hardening of the filament 32 for subsequent material handling operations.

[0108] In the configuration shown in FIG. 1, a part of the conveyor 132 located below the extrusion machine subsystem 20 and immersed in the fluid 134 is shown. The conveyor 132 can be spaced apart from the extrusion machine subsystem 20 and the funnel 64 such that there is sufficient space for the filament 32 to exit the funnel 64. The conveyor 132 may be disposed closer to the surface of the fluid 134 than shown. Further, it is contemplated that a part of the conveyor 132 can exit the fluid 134 to facilitate removal of the mesh cushion 12 from the tank 130.

[0109] In the configuration shown in FIG. 3, the material handling subsystem 24 can also include at least one mold 140. The mold 140 can be positioned on the belt of the conveyor 132, and the conveyor 132 can be configured to move the mold 140 relative to the extrusion machine subsystem 20. The mold 140 can define a mold cavity 142 that can deposit or discharge the filament 32 therein. The mold cavity 142 can open upward or in a direction facing the extrusion machine subsystem 20.

[0110] The mold 140 may or may not be positioned within the tank 130 when the filament 32 is deposited into the mold cavity 142. FIGS. 3 and 4 show an example where the mold 140 is partially contained within the fluid 134 when the filament 32 is deposited into the mold cavity 142. In a configuration where the extrusion machine subsystem 20 is stationary, the conveyor 132 can advance the mold 140 under the hopper 64 and relative to the hopper 64, thereby filling the mold cavity 142 with the filament 32. Thereafter, the mold 140 can be lowered into the fluid 134.

[0111] The mold 140 can be lowered or at least partially immersed in the fluid 134 in various ways. In the illustrated configuration, the conveyor 132 is configured to lower the mold 140 into the fluid 134. The conveyor 132 is inclined below the tank 130 such that as the mold 140 moves away from the hopper 64, the mold 140 is lowered into the fluid 134, thereby causing the fluid 134 to circulate through the filament 32 and the mold cavity 142 to cool and cure the filament 32. As another example, the mold 140 can be lowered into or lifted out of the fluid 134 without using the conveyor 132, such as by moving the mold 140 generally vertically or in a rotating loop that can access the fluid 134. It is also contemplated that the conveyor 132 can be omitted, or the mold 140 can be moved manually or in another way, such as during small batch production.

[0112] In the configuration shown in FIG. 4, the material handling subsystem 24 can be the same as or similar to that shown in FIG. 3. However, in FIG. 4, the extrusion machine subsystem 20 is attached to or connected to a robot manipulator 150.

[0113] The robot manipulator 150 can be movable along a plurality of axes and can have a plurality of degrees of freedom. For example, the robot manipulator 150 can be configured to move the extrusion machine subsystem 20 along a first axis 152, a second axis 154, and a third axis 156.

[0114] The first axis 152 can be a vertical axis.

[0115] The second axis 154 can be arranged perpendicular to the first axis 152 and can be a horizontal axis that extends in the left - right direction as viewed from the illustrated perspective.

[0116] The third axis 156 can be arranged perpendicular to the first axis 152 and the second axis 154 and can extend in the front - rear direction as viewed from the illustrated perspective.

[0117] The extrusion machine subsystem 20 can deposit the filament 32 into the mold cavity 142 when the mold 140 is stationary or moving. It is also contemplated that the conveyor 132 may be omitted during small - lot production, etc., or the mold 140 may be moved manually or by another method. The configuration shown in FIG. 4 and its related attributes will be considered in more detail later.

[0118] Referring to FIG. 1, control subsystem 26 can monitor and control the operation of system 10. For example, control subsystem 26 can include one or more control modules or electronic controllers 200 that can monitor and / or control the operation of one or more subsystems of system 10. For example, controller 200 can be electrically connected to or communicate with components of extrusion machine subsystem 20 such as feeder 42 and roller drive unit 54, environmental control subsystem 22, material handling subsystem 24, or combinations thereof, and can be a microprocessor-based controller. If robot manipulator 150 is provided, controller 200 can also control its operation. For simplicity, FIG. 1 shows a single controller, but it is contemplated that control subsystem 26 may be provided with multiple control modules or controllers, or a distributed control architecture. Control subsystem 26 is also provided in the configurations shown in FIGS. 3 and 4, but is omitted from these figures for clarity only.

[0119] Controller 200 can also process input signals or data from various input devices or sensors. Input devices that can be provided in system 10 can include temperature sensor 160 and humidity sensor 162.

[0120] Temperature sensor 160 can provide a signal indicating the temperature of the air within chamber 80. Temperature sensor 160 can be of any suitable type, such as a thermistor, thermocouple, semiconductor-based temperature sensor, infrared sensor, etc. Temperature sensor 160 can be provided at any suitable location. For example, temperature sensor 160 can be provided within chamber 80 or in environmental control subsystem 22.

[0121] The humidity sensor 162 can provide a signal indicating the humidity of the air within the chamber 80. The humidity sensor 162 can be of any suitable type, such as a capacitance-type humidity sensor, a resistance-type humidity sensor, or a thermal conductivity-type humidity sensor. The humidity sensor 162 can be provided at any suitable location. For example, the humidity sensor 162 may be provided within the chamber 80, or may be provided in the environmental control subsystem 22.

[0122] Referring again to FIG. 4, the robotic manipulator 150 can be configured to move the extrusion machine subsystem 20 to vary the filament density of the mesh cushion 12. For example, the material 30 can be extruded through the filament-forming openings 70 of one or more die plates 60 at a substantially constant flow rate. Thus, it can be expected that the filaments 32 will have substantially the same diameter or thickness when the filament-forming opening size is constant. However, the filaments 32 become thinner as the distance from the die plate 60 and the filament-forming openings 70 increases. This is best understood with reference to FIGS. 5A and 5B.

[0123] FIG. 5A shows an enlarged view of a portion of the die plate 60 and the filament-forming openings 70. The die plate 60 is positioned at a first distance Z1 above the surface S.

[0124] In FIG. 5B, the die plate 60 is positioned at a second distance Z2 above the surface S, and Z1 is smaller than Z2. The filament 32 extends over an increased distance and becomes thinner because the material 30 is in a molten and uncured state, so in FIG. 5B it is thinner or has a smaller diameter at the surface S. These properties can be used to vary the filament density of the mesh cushion 12. For example, the robotic manipulator 150 can move the die plate 60 upward or away from the mold 140 to reduce the size, thickness or diameter of the filament 32 when deposited within the mold 140. Conversely, the robotic manipulator 150 can move the die plate 60 towards the mold 140 to increase the size, thickness or diameter of the filament 32 when deposited within the mold 140.

[0125] The robotic manipulator 150 can also vary the filament density in other ways by moving the die plate 60 while the filament 32 is being deposited. For example, the robotic manipulator 150 can repeatedly move the die plate 60 towards and then away from the mold 140, and / or reduce its movement speed, and / or increase its dwell time to increase the filament density. As another example, the robotic manipulator 150 can move the die plate 60 faster in the horizontal plane (i.e., along the second axis 154 and / or the third axis 156) or spend less time in a particular area to reduce the filament density. Conversely, the robotic manipulator 150 can move the die plate 60 slower in the horizontal plane or spend more time in a particular area to increase the filament density. Thus, the filament density increases as the time spent in a particular area increases, thereby allowing more filaments to be deposited, and the filament density can decrease as the time spent in a particular area decreases.

[0126] It should also be noted that in FIG. 4, various components of the environmental control subsystem 22 and the extrusion machine subsystem 20, such as the portion of the housing 62 located below the die plate 60, the hopper 64, or both, may be omitted.

[0127] Here, with reference to FIGS. 6A - 8B, an example of an extrusion machine subsystem configuration having an interchangeable die plate or a plurality of die plates will be considered. The plurality of die plates can be given any of the previously considered extrusion machine subsystem configurations, such as the configurations shown in FIGS. 1, 3, and 4.

[0128] FIGS. 6A and 6B show examples of two different die plates. The die plates 60, 60' have the same size and shape but do not have the same number of filament - forming openings 70. The die plate 60 in FIG. 6A has more filament - forming openings 70 than the die plate 60' in FIG. 6B. Therefore, the number of filaments 32 that can be provided by the die plate 60 in FIG. 6A is greater than the number of filaments 32 that can be provided by the die plate 60' in FIG. 6B. Thus, when there is a certain material flow rate and discharge time, by using the die plate 60' in FIG. 6B as compared to the die plate 60 in FIG. 6A, a mesh cushion 12 with a lower filament density can be provided.

[0129] Referring to FIG. 7, a configuration having two stacked die plates is shown. It is noted that it is contemplated that three or more die plates may be provided in a stacked arrangement initially.

[0130] The configuration of FIG. 7 will be considered mainly in the context of a first die plate and a second die plate that are directly stacked on each other. For clarity, the lower die plate is referred to as the first die plate, and the die plate placed on top of the first die plate is referred to as the second die plate, but it is contemplated that the positioning of the first die plate and the second die plate may be changed or reversed, or additional die plates may be provided.

[0131] As an example, the first die plate 60 can be configured as shown in FIG. 6A. The first die plate 60 can have a first set of filament-forming openings 70. In at least one configuration, the elements of the first set of filament-forming openings 70 can be given the same configuration.

[0132] Referring to FIGS. 7 and 8A, an example of a second die plate 260 is shown. The second die plate 260 can be disposed adjacent to the first die plate 60 and can have a second set of filament-forming openings 270. The elements of the second set of filament-forming openings 270 may or may not have the same configuration. For example, in FIG. 8A, not all of the elements of the second set of filament-forming openings 270 have the same configuration. Instead, some of the filament-forming openings 270 have the same configuration as the filament-forming openings 70 of the first die plate 60 (represented as circles in FIG. 8A), and some of the filament-forming openings 270 are larger than the filament-forming openings 70 of the first die plate 60 (represented as elongated elliptical slots in FIG. 8A). It is also contemplated that the second set of filament-forming openings 270 may have fewer elements than the first set of filament-forming openings 70.

[0133] The relative positioning of the second die plate 260 with respect to the first die plate 60 can be adjusted to change the alignment of the filament-forming openings 70, 270 relative to each other. The change in alignment can be achieved by moving the first die plate 60 or a part thereof relative to the second die plate 260, by moving the second die plate 260 or a part thereof relative to the first die plate 60, or by both. As an example, the first die plate 60 can be held in a stationary position, and the second die plate 260 can be slid or moved along the first die plate 60 such that the second die plate 260 closes at least a part of the filament-forming openings 70 of the first die plate 60. This is best understood by comparing FIGS. 8A and 8B.

[0134] In FIG. 8A, the second die plate 260 is shown in an example in a first position. In this example, when the second die plate 260 is in the first position, it does not block any of the filament-forming openings 70 of the first die plate 60. Thus, the material 30 can be extruded through the second set of filament-forming openings 270 and then through the corresponding elements of the first set of filament-forming openings 70 that are aligned with the elements of the second set of filament-forming openings 270 to form the filaments 32.

[0135] In FIG. 8B, as compared with FIG. 8A, the relative positioning of the first die plate 60 and the second die plate 260 is changed. In the example of FIG. 8B, the first die plate 60 remains in the same position as in FIG. 8A, and the second die plate 260 has moved to a second position different from the first position. As a result, some of the elements of the second set of filament-forming openings 270 remain aligned with the corresponding elements of the first set of filament-forming openings 70, while other elements of the second set of filament-forming openings 270 are no longer aligned with the elements of the first set of filament-forming openings 70. Accordingly, the second die plate 260 is positioned so as to prevent the material from reaching and passing through the elements of the first set of filament-forming openings 70.

[0136] More specifically, in the illustrated example, the elements of the second set of filament-forming openings 270 having a circular shape are no longer aligned with any of the elements of the first set of filament-forming openings 70, whereas the elongated elliptical-shaped elements of the second set of filament-forming openings 270 have been repositioned but still remain sufficiently aligned with the corresponding elements of the first set of filament-forming openings 70 to allow the material 30 to be extruded through the aligned filament-forming openings 70. Accordingly, the larger elements (i.e., the elliptical-shaped elements) of the second set of filament-forming openings 270 can allow the material 30 to flow through the corresponding elements of the first set of filament-forming openings 70 when the second die plate 260 is in the first position and when it is in the second position. As a result, the filaments 32 are extruded when the second die plate 260 is in the first position and when it is in the second position, but when the second die plate 260 is in the second position, the number of filaments 32 formed by the die set is reduced.

[0137] It is contemplated that the die plate may move in a manner different from that previously described. As one example, the die plate may be divided into a plurality of portions that can move independently. For example, the second die plate 260 may be divided in half, and each half of the second die plate 260 may be movable to selectively block or enable the flow of material 30 through a subset of the first set of filament-forming openings 70.

[0138] As another example, the die plate may be rotatable about an axis rather than movable in a linear direction.

[0139] As another example, a plurality of die plate regions may be integrated into a single plate that can be rotated about an axis. Each die plate region may have a different pattern of filament-forming openings. Next, the single plate can be rotated about the axis to align a particular die plate region with another die plate. As a result, each die plate region can provide a different number of filaments when positioned adjacent to or aligned with another die plate.

[0140] It is also contemplated that the second die plate 260 may be movable to a position that blocks all of the elements of the first set of filament-forming openings 70 of the first die plate 60, thereby ending the flow of material through the die plate and ending the extrusion of the filaments 32.

[0141] Although exemplary embodiments have been described above, it is not intended that these embodiments represent all possible forms of the invention. In that regard, the language used herein is for descriptive purposes and not of limitation, and it is understood that various changes can be made without departing from the spirit and scope of the present disclosure. Additionally, the features of the various embodiments can be combined to form further embodiments of the invention. [Document Name]Claims [Claim 1] A method of manufacturing a mesh cushion, comprising: Extruding a material through a plurality of filament-forming openings in a die plate to form a plurality of filaments; Depositing the filaments onto a first roller and a second roller, wherein the first roller is rotatable about a first axis and defines a first recess, and the second roller is rotatable about a second axis and defines a second recess; Rotating the first roller and the second roller to guide the filaments into the first recess and the second recess and through a gap between the first roller and the second roller, thereby forming the filaments as the mesh cushion having a variable cross-sectional shape; A method comprising the above steps. [Claim 2] The method according to claim 1, wherein the first roller and the second roller are spaced apart from the die plate and positioned below the die plate. [Claim 3] The method according to claim 1, wherein the filaments are deposited while the first roller and the second roller are rotating. [Claim 4] The method according to claim 1, wherein the first recess and the second recess do not have mirror symmetry. [Claim 5] The first roller includes a first central portion that serves as a starting point where the first recess extends, and a first end plate that is rotatable about the first axis together with the first central portion and extends further from the first axis than the first central portion. The first end plate overlaps the second roller to guide the filaments into the gap between the first roller and the second roller. The method according to claim 1. [Claim 6] The second roller includes a second central portion that is a starting point from which the second recess extends, and a second end plate that is rotatable about the second axis together with the second central portion and extends further from the second axis than the second central portion. The second end plate overlaps the first roller and guides the filament into the gap between the first roller and the second roller. The method according to claim 5. [Claim 7] The first end plate of the first roller and the second end plate of the second roller overlap each other and guide the filament into the gap between the first roller and the second roller. The method according to claim 6. [Claim 8] At least a part of the first roller and the second roller is positioned above a funnel that defines a funnel opening through which the material passes. The method according to claim 1. [Claim 9] The filament extruded through the die plate is provided in a chamber that is partially defined by a housing that extends between the die plate and the funnel. The method according to claim 8. [Claim 10] The first roller and the second roller are at least partially accommodated within the chamber. The method according to claim 9. [Claim 11] An environmental control subsystem controls the temperature and humidity of the air within the chamber to control the thickness of the filament. The method according to claim 9. [Claim 12] A method of manufacturing a mesh cushion, extruding a material through a plurality of filament-forming openings of a die plate to form a plurality of filaments, guiding the filament into a funnel to solidify and engage the filament, depositing the filament within a mold, Dipping the mold at least partially into a fluid to cool and cure the filament to form the mesh cushion; A method comprising. [Claim 13] The method according to claim 12, wherein the mold is disposed on a conveyor, and the conveyor moves the mold into the fluid. [Claim 14] The method according to claim 12, wherein the mold is partially received in the fluid when the filament is deposited. [Claim 15] The method according to claim 12, wherein the filament extruded through the die plate is provided in a chamber including a housing extending between the die plate and the funnel. [Claim 16] A method of manufacturing a mesh cushion, comprising: Extruding a material through a plurality of filament-forming openings in a die plate to form a plurality of filaments, wherein the die plate is connected to a robotic manipulator configured to move the die plate along a plurality of axes; Depositing the filaments into a mold; Dipping the mold at least partially into a fluid to cool and cure the filament, thereby forming the filament as the mesh cushion, wherein the robotic manipulator moves the die plate when depositing the filament to vary the filament density of the mesh cushion; A method comprising. [Claim 17] The method according to claim 16, wherein the material is extruded through the plurality of filament-forming openings at a substantially constant flow rate. [Claim 18] The method according to claim 16, wherein the robotic manipulator moves the die plate away from the mold to reduce the diameter of the filament when depositing into the mold. [Claim 19] The method according to claim 16, wherein the robot manipulator moves the die plate towards the mold to increase the diameter of the filament when depositing in the mold. [Claim 20] The method according to claim 16, wherein the robot manipulator moves the die plate at high speed in a horizontal plane to reduce the filament density and moves at low speed to increase the filament density. [Document Name] Abstract [Abstract] A method of manufacturing a mesh cushion. The method includes extruding a material through a plurality of filament-forming openings of at least one die plate to form a plurality of filaments. The filaments can be at least partially immersed in a fluid to cool and cure the filaments into a mesh cushion. [Figure 1] JPEG2025520583000002.jpg178130[Figure 2] JPEG2025520583000003.jpg146131[Figure 3] JPEG2025520583000004.jpg200131[Figure 4] JPEG2025520583000005.jpg168140[Figure 5A] JPEG2025520583000006.jpg12380[Figure 5B] JPEG2025520583000007.jpg16377[Figure 6A] JPEG2025520583000008.jpg66168[Figure 6B] JPEG2025520583000009.jpg72168[Figure 7] JPEG2025520583000010.jpg73149[Figure 8A] JPEG2025520583000011.jpg91143[Figure 8B] JPEG2025520583000012.jpg115131

Claims

1. An elongate member attached to a trim cover, A plurality of anchors extending from the elongate member, each of the plurality of anchors having a body having a first end attached to the elongate member and a second end opposite the first end, the second end terminating in a sharp tip, each of the plurality of anchors having a plurality of barbs, each barb extending from the body in a direction away from the tip, the plurality of anchors, Comprising, For each of the plurality of anchors, a retainer in which a cushioning material is gripped between the body and each of the plurality of barbs when the anchor is inserted into the cushion.

2. The retainer according to claim 1, wherein the elongate member includes a planar strip.

3. The retainer according to claim 1 or 2, wherein each of the plurality of anchors is planar.

4. The retainer according to any one of claims 1 to 3, wherein the elongate member is sewn to the trim cover.

5. The retainer according to any one of claims 1 to 4, wherein the plurality of anchors are spaced apart along the elongate member such that adjacent anchors are equidistant.

6. The retainer according to any one of claims 1 to 5, wherein the elongate member and the plurality of anchors are formed as a single piece.

7. The retainer according to any one of claims 1 to 6, wherein the retainer is formed by injection molding or by stamping or cutting from a sheet.

8. The retainer according to any one of claims 1 to 7, wherein the sharp tip pierces the cushioning material.

9. The retainer according to any one of claims 1 to 8, wherein the cushioning material includes a mesh formed from filaments looped and joined together.

10. The retainer according to claim 9, wherein the filaments are extruded and formed as a three-dimensional structure.

11. The retainer according to any one of claims 1 to 10, wherein the cushioning material has no recesses formed to receive the plurality of anchors.

12. A cushion, A trim cover, A retainer according to any one of claims 1 to 11 for attaching the trim cover to the cushion, A seat assembly comprising.

13. A method of assembling a seat assembly, comprising: providing a retainer having an elongate member and a plurality of anchors extending from the elongate member, each of the plurality of anchors having a body with a first end attached to the elongate member and a second end opposite the first end, the second end terminating in a sharp tip, each of the plurality of anchors having a plurality of barbs, each barb extending from the body in a direction away from the tip; attaching the elongate member to a trim cover; inserting the plurality of anchors into a cushion, wherein for each of the plurality of anchors, the material of the cushion is gripped between the plurality of barbs and the body.

14. The method of claim 13, wherein inserting the plurality of anchors into the cushion includes piercing the material of the cushion with the tip of each anchor.

15. The method of claim 13 or 14, wherein the elongate member includes a planar strip, and attaching the elongate member to the trim cover includes sewing the elongate member to the trim cover.

16. The method according to any one of claims 13 to 15, wherein the plurality of anchors are spaced along the elongate member such that the distance between adjacent anchors is equal.

17. The method according to any one of claims 13 to 16, wherein the elongate member and the plurality of anchors are an integral member.

18. The method according to any one of claims 13 to 17, further comprising providing a cushion formed of a three-dimensional mesh structure of looped and joined filaments.

19. The method of claim 18, wherein the filaments are extruded and formed as the three-dimensional mesh structure.

20. The method according to any one of claims 13 to 19, wherein the material of the cushion has no recesses formed to receive the plurality of anchors.

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