Extruded plastic mesh, seating assembly, cushion and / or method of formation

Abstract

The seat support is provided with a plurality of flat layers that are attached to the seat frame and support passengers on the seat frame. The plurality of flat layers are stacked on top of each other, and each of the plurality of stacked layers has a different density. The seat support is provided with one or more layers of an extruded thermoplastic resin mesh that are attached to the seat frame and support passengers on the seat frame. The plurality of layers can be stacked on top of each other.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Patent Application No. 63 / 351,902, filed on June 14, 2022; U.S. Patent Application No. 63 / 356,555, filed on June 29, 2022; U.S. Patent Application No. 63 / 355,754, filed on June 27, 2022; U.S. Patent Application No. 63 / 355,793, filed on June 27, 2022; U.S. Patent Application No. 63 / 355,700, filed on June 27, 2022; U.S. Patent Application No. 63 / 357,056, filed on June 30, 2022; U.S. Patent Application No. 63 / 355,158, filed on June 24, 2022; and Danish Patent Application No. PA202370197, filed on April 25, 2023, and the entire disclosures of these are incorporated herein by reference.

[0002] Various embodiments relate to vehicle seat components, seat cushions, seat assemblies, methods of manufacturing seat cushions, and methods of designing seat cushions.

[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 refer to like elements.

Brief Description of the Drawings

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BEST MODE FOR CARRYING OUT THE INVENTION

[0005] Hereinafter, embodiments will be referred to in detail, and examples thereof are shown in the accompanying drawings. In the following detailed description, many specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0006] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Accordingly, the details regarding specific structures and functions disclosed herein should not be construed as limiting, but rather as a representative basis for teaching those skilled in the art to variously adopt the embodiments according to the disclosure.

[0007] "One or more" includes that a function is performed by one element, that a function is performed by two or more elements, for example, in a distributed manner, that some functions are performed by one element, that some functions are performed by some elements, or any combination of the above.

[0008] The terms first, second, etc. are used herein in some instances to describe various elements, but it should also be understood that these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first surface can be referred to as the second surface, and similarly, the second surface can be referred to as the first surface. The first surface and the second surface are both surfaces, but they are not the same surface.

[0009] The terms used in the description of the various described embodiments herein are for the purpose of describing only specific embodiments and are not intended to be limiting. When used in the description of the various described embodiments and the appended claims, the singular forms "one", "a", and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise.

[0010] As used herein, the term "and / or" refers to any and all possible combinations of one or more of the associated listed items, and it should also be understood to encompass them. For example, the term "and / or" means that all or only one of the elements of the above-mentioned group may be present. For example, "A and / or B" shall mean "only A or only B or both A and B". In the case of "only A", this term also encompasses the possibility that B does not exist, that is, the possibility of "only A and no B".

[0011] The terms "includes" and / or "comprises", as used herein, when used, specify the presence of the stated features, integers, steps, operations, elements and / or parts, but it should be further understood that they do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts and / or groups thereof.

[0012] As used herein, the term "if" is optionally, depending on the context, construed to mean "when" or "upon" or "in response to determining" or "in response to detecting". Similarly, the phrases "when determined" or "when [stated condition or event] is detected" are optionally, depending on the context, construed to mean "when determined" or "in response to determining" or "when [stated condition or event] is detected" or "in response to [stated condition or event] being detected".

[0013] Except in the case of the examples or unless otherwise explicitly indicated, all quantities in this specification indicating amounts of materials or conditions of reactions and / or use are to be understood as being modified by the word "about" when describing the broadest scope of the invention. Implementation within the limits of the recited numerical values is generally preferred. Also, unless otherwise specified, percent, "parts" and ratio values are by weight, the term "polymer" includes "oligomer", "copolymer", "terpolymer", etc., the molecular weight provided for any polymer refers to the weight average molecular weight unless otherwise indicated, a description of a group or class of materials as being suitable or preferred for a given purpose related to the present invention implies that any mixture of two or more of the members of that group or class is equally suitable or preferred, a description of a component in chemical terms refers to the component upon addition to any combination specified in the description and does not necessarily exclude chemical interactions between the components of a mixture once mixed, the initial definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation in this specification and is applied mutatis mutandis to the normal grammatical variations of the initially defined abbreviation, and unless otherwise specified, measured values of properties are determined by the same techniques as previously or later referenced for the same property.

[0014] As used herein, the term "about" means that the quantity or value in question can be some other value near or at the specified particular value. Generally, the term "about" indicating a particular value is intended to indicate a range within ±5% of that value. As one example, the phrase "about 100" indicates a range of 100 ± 5, i.e., a range of 95 to 105. Generally, when the term "about" is used, it can be expected that similar results or effects according to the present invention can be obtained within a range of ±5% of the indicated value.

[0015] It should also be understood that, since specific components and / or conditions can of course vary, the present invention is not limited to the specific embodiments and methods described below. Moreover, the terminology used herein is for the purpose of describing particular embodiments of the invention only and is not intended to be limiting at all.

[0016] The term "comprising" is synonymous with "including", "having", "containing" or "characterized by". These terms are inclusive and without limitation and do not exclude additional, unrecited elements or method steps.

[0017] The phrase "consisting of" excludes any element, step or component not specified in the claim. When this phrase appears not immediately following the preamble but in a clause of the body of the claim, it limits only the elements recited in that clause and other elements are not excluded from the claim as a whole.

[0018] The phrase "consisting essentially of" limits the claim to those things that do not materially affect the basic and novel characteristics (which may be plural) of the claimed subject matter in addition to the specified materials or steps.

[0019] The phrase "composed of" means "including" or "consisting of". Typically, this phrase is used to indicate that an object is formed from materials.

[0020] With respect to the terms "comprising", "consisting of" and "consisting essentially of", when one of these three terms is used herein, the subject matter of the present disclosure can include the use of either of the other two terms.

[0021] The term "one or more" means "at least one", and the term "at least one" means "one or more". The terms "one or more" and "at least one" include "plurality" as a part (subset). In certain definitions, "one or more" includes "two or more".

[0022] The terms "substantially", "generally" or "about" may be used herein to describe the disclosed or claimed embodiments. The term "substantially" may modify a value or relative characteristic disclosed or claimed in the present 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 that value or relative characteristic.

[0023] Also, a range of integers explicitly includes all intervening integers. For example, the integer range 1 to 10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4, ··· 97, 98, 99, 100. Similarly, when any range is specified, the intervening numbers that are the increment obtained by dividing the difference between the upper and lower limits by 10 can be adopted as alternative upper or lower limits. For example, when 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 the lower or upper limit.

[0024] When referring to a quantity, in certain definitions, the term "less than" includes a lower limit value that is not included and is 5 percent of the number indicated before "less than". For example, "less than 20" includes 1 as the lower limit value that is not included in certain definitions. Therefore, "less than 20" in this definition includes the range 1 to 20. In another definition, the term "less than" includes a lower limit value that is not included and is 20 percent, 10 percent, 5 percent or 1 percent of the number indicated before "less than" in ascending order of preference.

[0025] Seat assemblies and vehicle seat assemblies are designed and manufactured in light of various specifications including support, comfort, performance, heating, ventilation, cooling, adjustability, etc. Seat assemblies often include a frame and various layers of foam having different densities adapted to the applicable load distribution across the seat assembly.

[0026] FIG. 1 shows a seat assembly 20 according to one embodiment. Seat assembly 20 is shown as a vehicle seat that can be employed as a seat assembly in a land vehicle, aircraft, ship, etc. Seat assembly 20 can be employed in any row within a vehicle. Alternatively, seat assembly 20 can also be employed as an office chair or any personal chair. Seat assembly 20 omits conventional foam in order to improve support and comfort while reducing cost, materials, and dimensions. Seat assembly 20 can also employ recycled materials manufactured to be recycled further at the end of the use of seat assembly 20.

[0027] Seat assembly 20 includes a seat bottom 22 sized to receive a seated occupant and support the occupant's pelvis and thighs. Seat assembly 20 also includes a seat back 24 extending upright from seat bottom 22 and sized to support the occupant's back. A headrest can be supported above and over seat back 24 to support the occupant's head. Seat bottom 22 is adapted to be supported by a supporting surface below. In the illustrated embodiment, seat assembly 20 includes a pair of rails 28 for attaching seat bottom 22 to a vehicle floor such that seat bottom 22 can be adjusted back and forth relative to the vehicle floor. Seat back 24 can also be made adjustable to recline relative to seat bottom 22. The headrest can also be made adjustable in height, tilt, and fore-and-aft directions. As is known in the art, other adjustments can be provided.

[0028] The seat bottom 22 includes a frame 30 for providing a rigid structural support to the seat bottom 22. The seat back 24 can also include a frame connected to the seat bottom frame 30 that extends upright from the seat bottom 22 and provides a rigid structural support to the seat back 24. The frame 30 can be formed from a punched steel alloy, a fiber-reinforced polymer, or any suitable structural material.

[0029] Conventional seat assemblies include multiple foam layers that collectively provide cushioning on the frame 30. The foam layers have different densities and provide a flexible support to the occupant while dispersing the forces from the occupant to the frame 30. The foam layers also provide comfort to the occupant. Since the foam layers are often molded, dedicated machinery is required for each foam layer of each seat assembly.

[0030] The seat assembly 20 is formed without foam to reduce the machinery cost associated with manufacturing while improving comfort, performance, compactness, and recyclability. For example, the seat assembly 20 includes a seat bottom support 36 that provides a seat bottom cushion for the seat bottom 22. The seat bottom support 36 is formed from a plurality of stacked layers of non-foam material. The seat back 24 similarly includes a seat back support 38 formed from stacked non-foam layers. Similarly, the headrest can also include a headrest support formed from stacked non-foam layers.

[0031] FIG. 1 shows a plurality of stacked layers 40, 42, 44, 46, 48, 50, 52 employed to construct the seat bottom support 36, the seat back support 38, and the headrest support. Each of the stacked layers 40, 42, 44, 46, 48, 50, 52 may have a different material density. The stacked layers 40, 42, 44, 46, 48, 50, 52 may have a continuously decreasing material density and hardness from the base layer 40 to the intermediate layers 42, 44, 46, 48, 50 and the comfort layer 52. The stacked layers 40, 42, 44, 46, 48, 50, 52 provide a transition in density and hardness from the comfort support at the passenger contact surface in the comfort layer 52 to the structural support in the base layer 40.

[0032] In the illustrated embodiment, the base layer 40 may be formed from a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, or foamed polyvinyl chloride. The base layer 40 can provide a substrate or housing for the intermediate layers 42, 44, 46, 48, 50 and the comfort layer 52. The base layer 40 can be directly attached to the frame 30. The base layer 40 may have a suitable thickness such as 2 millimeters or less.

[0033] The stacked layers 40, 42, 44, 46, 48, 50, 52 are shown as a plurality of sheets in FIG. 2. Sheets 40, 42, 44, 46, 48, 50, 52 are each unwound from a roll of material. Sheets 40, 42, 44, 46, 48, 50, 52 are unwound flat. The flatness is generally planar within manufacturing tolerances. Each of the rolls of material can be a roll of material readily available in the market, such as materials employed for vehicle interiors, floor coverings, acoustics, etc. Examples of such materials include rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate, linear low-density polyethylene, polypropylene, and the like. By utilizing existing materials, the material and manufacturing costs are reduced as compared to molding a foam cushion from dedicated machinery. The materials may also be formed from recycled materials to reduce material costs and waste. According to another embodiment, one or more of layers 40, 42, 44, 46, 48, 50, 52 may be formed from an extruded thermoplastic resin mesh as described in subsequent embodiments.

[0034] After layers 40, 42, 44, 46, 48, 50, 52 are unwound as sheets 40, 42, 44, 46, 48, 50, 52, the sheets 40, 42, 44, 46, 48, 50, 52 are then die cut into the shape of seat support layers 40, 42, 44, 46, 48, 50, 52 to collectively provide the contour of seat bottom 22. The seat support layers 40, 42, 44, 46, 48, 50, 52 are then stacked and connected or joined together. The seat support layers 40, 42, 44, 46, 48, 50, 52 can be welded, sewn, fastened, adhered, or otherwise connected to adjacent seat support layers 40, 42, 44, 46, 48, 50, 52 in succession. Alternatively, the sheets 40, 42, 44, 46, 48, 50, 52 may be stacked or stacked and joined prior to the cutting operation. The cutting operation can be performed by one or more dies. The machinery cost for the die cutting die provides a reduction in capital cost compared to a dedicated mold. Alternatively, robotic laser cutting or other flexible automated machinery operations that can program the cutouts of various seat configurations can be employed to reduce the machinery cost.

[0035] Layers 40, 42, 44, 46, 48, 50, 52 can be customizable. Each of the layers 40, 42, 44, 46, 48, 50, 52 can be formed with a specific hardness and thickness, such that different combinations of the layers 40, 42, 44, 46, 48, 50, 52 can be employed to optimize specific support and comfort curve profiles for various sheets. The comfort curve profile is created by the estimated pressure distribution across seat assembly 20 based on the design characteristics for the occupant, which is set based on the predicted height, weight, and other data for the targeted range of occupants. A seat assembly 20 designed to utilize the stacked layers 40, 42, 44, 46, 48, 50, 52 instead of polyurethane foam to provide the same static comfort has a reduced weight compared to the same seat assembly made of foam. In addition, the stacked layers 40, 42, 44, 46, 48, 50, 52 allow for increased design flexibility to reduce the pressure in the peak regions of seat assembly 20.

[0036] Figure 3 shows the seat support 54 according to some embodiments. The housing or base material 40 may be formed with a contour instead of being formed from a flat sheet 40. Then, the intermediate layers 42, 44, 46 and the comfort layer 52 are installed on the base material 40.

[0037] Referring back to FIG. 1, when the stacked layers 40, 42, 44, 46, 48, 50, 52 are assembled, the seat supports 36, 38 are installed within the seat assembly 20. Trim covers 60, 62 are provided over each seat support 36, 38 to house and conceal the seat supports 36, 38.

[0038] By eliminating the foam from the seat assembly 20, the molding and die can be eliminated, thereby reducing the mechanical equipment cost. The flexibility of die cutting, laser cutting or other flexible automated machining operations reduces the maintenance cost and improves the quality of the parts. The recyclability of the materials reduces the scrap waste. In addition, the amount of chemicals used in the manufacturing process is reduced.

[0039] The seat assembly 20 is lighter than an equivalent seat manufactured with a foam cushioning material. The seat assembly 20 is also more compact in dimensions, such as having a depth of 35 millimeters to 40 millimeters, while providing similar or improved comfort. The targeted comfort layer is provided and can be easily redesigned for future models or options without additional mechanical equipment cost.

[0040] Figure 3B shows a method 400 according to some embodiments. The method 400 is used to manufacture a seat assembly (e.g., seat assemblies 20, 120, 210, 310, 410, 520, 620), which can be a vehicle seat, an office chair, a personal chair, etc. In various examples, the method 400 can have more or fewer steps than those described below, and the various steps can be performed in a different order, continuously, or simultaneously. The method 400 can be a method of manufacturing a product that can be a vehicle seat, an office chair, a personal chair, a cushion, a seat support, a seat bottom cushion, a seat back cushion, a headrest, etc.

[0041] Method 400 may or may not have a foam, and includes unwinding (402) a first sheet that may generally be planar within manufacturing tolerances, of a first material that may or may not have a foam, and may be rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, a sheet of recycled material, and / or each may be unwound from a roll of material. Each roll of material can be a material roll readily available on the market, such as materials employed for vehicle interiors, floor coverings, acoustics, etc. Method 400 includes cutting (404), for example, from the first sheet, a first seat support layer (e.g., intermediate layer 42) for a seat bottom, seat back, headrest, etc., by die cutting, robotic laser cutting, water jet cutting, laser cutting, or other flexible automated machining operations, and installing (406) the first seat support layer (e.g., intermediate layer 42) on a substrate (e.g., 40) that can be a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or foamed polyvinyl chloride. The base layer can provide a substrate, i.e., a housing, for the intermediate layer, and the comfort layer may be formed with a contour instead of being formed from a flat sheet. Method 400 includes unwinding (408) a second sheet that may generally be planar within manufacturing tolerances, of a second material that has a density lower than that of the first material and can provide a density and hardness transition from the comfort support at the passenger contact surface in the comfort layer to the structural support in the base layer. The second material may or may not have a foam, and may be rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, a sheet of recycled material, and / or each may be unwound from a roll of material. Each roll of material can be a material roll readily available on the market, such as materials employed for vehicle interiors, floor coverings, acoustics, etc.Method 400 includes cutting (410), for example, from a second seat, a second seat support layer (such as intermediate layer 44) for a seat bottom, seat back, headrest, etc., by die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automated machining operations that can be performed, and installing (412) the second seat support layer (such as intermediate layer 44) on the first seat support layer (such as intermediate layer 42).

[0042] In some embodiments, method 400 includes unrolling a third sheet that can be generally planar within manufacturing tolerances of a third material having a density lower than that of the second material and providing a transition in density and hardness from a comfort support at a passenger contact surface in a comfort layer to a structural support in a base layer. The third material may or may not have a foam, and can be rubber, carpet, needle punched cotton recycled wool, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, a sheet of recycled material, and / or each can be unrolled from a roll of material. Each of the rolls of material can be a roll of material readily available in the market, such as materials employed in vehicle interiors, flooring, acoustics, etc. Method 400 includes cutting a third seat support layer (such as intermediate layer 46) from the third sheet by die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automated machining operations that can be performed, and installing the third seat support layer (such as intermediate layer 46) on the second seat support layer (such as intermediate layer 44).

[0043] In some embodiments, method 400 includes joining the second seat support layer (such as intermediate layer 44) to the first seat support layer (such as intermediate layer 42). Joining can be provided by a retaining clip having an end embedded in a foam and a retaining clip end attached to a plastic mesh base, a hook and loop connection strip, a hook layer, a loop layer, an adhesive, hog rings, a single-sided or double-sided retaining clip, welding, sewing, fastening, adhesion, heat caulking, and / or other forms of retention.

[0044] A seat assembly (e.g., seat assembly 20) that can be a vehicle seat, an office chair, a personal chair, etc. is described. In some embodiments, the seat assembly (e.g., 20, 120, 210, 310, 410, 520, 620) is manufactured using method 400.

[0045] A seat support (e.g., seat supports 36, 38 and / or 54) that can be a seat bottom cushion, a seat back cushion, a headrest, a headrest, a bolster, a region, a portion, etc. is described. The seat support (e.g., seat supports 36, 38 and / or 54) can be generally planar within manufacturing tolerances and may or may not have a foam, and includes a plurality of flat layers (e.g., intermediate layers 42 - 50) that can be rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, a sheet of recycled material and / or each can be unrolled from a roll of material. Each of the rolls of material can be a material roll readily available in the market, such as materials employed in vehicle interiors, floor coverings, acoustics, etc. The plurality of flat layers are attached to a seat frame, a wire suspension mat, a substrate and / or a panel that can be a punched steel alloy, a fiber-reinforced polymer or any suitable structural material, and support a passenger on the seat frame. The plurality of flat layers (e.g., intermediate layers 42 - 50) are stacked on top of each other (e.g., as shown in FIGS. 2 and 3), and each of the plurality of stacked layers has a different density and can provide a transition in density and hardness from comfortable support at the passenger contact surface in the comfort layer to structural support in the base layer.

[0046] In some embodiments, the plurality of stacked layers (e.g., intermediate layers 42-50) differ such that the density continuously increases from the passenger support surface (e.g., layer 52) to the base layer (e.g., layer 42), thereby providing a transition in density and hardness from the comfortable support at the passenger contact surface in the comfort layer to the structural support in the base layer, which may include high-density materials such as elastomers, ethylene propylene diene monomer rubbers, thermoplastic polyurethanes, and / or foamed polyvinyl chloride. The base layer can provide a substrate or housing for the intermediate and comfort layers.

[0047] In some embodiments, the plurality of stacked layers (e.g., intermediate layers 42-50) differ such that the hardness continuously increases from the passenger support surface (e.g., layer 52) to the base layer (e.g., layer 42), thereby providing a transition in density and hardness from the comfortable support at the passenger contact surface in the comfort layer to the structural support in the base layer, which may include high-density materials such as elastomers, ethylene propylene diene monomer rubbers, thermoplastic polyurethanes, and / or foamed polyvinyl chloride. The base layer can provide a substrate or housing for the intermediate and comfort layers.

[0048] In some embodiments, the plurality of stacked layers (e.g., intermediate layers 42-50) are connected together, and the connection can be by means of a retaining clip having an end embedded in the layer and a retaining clip end attached to a plastic mesh base, a hook and loop connection strip, a hook layer, a loop layer, an adhesive, hog rings, single-sided or double-sided retaining clips, joining, welding, sewing, fastening, adhesion, heat staking, and / or retention.

[0049] In some embodiments, each successive pair of the plurality of stacked layers (e.g., layers 42 and 44; layers 46 and 48) are joined together, and the joining can be by means of a retaining clip having an end embedded in the layer and a retaining clip end attached to a plastic mesh base, a hook and loop connection strip, a hook layer, a loop layer, an adhesive, hog rings, single-sided or double-sided retaining clips, welding, sewing, fastening, adhesion, heat staking, and / or retention.

[0050] In some embodiments, each consecutive pair of the plurality of stacked layers (e.g., intermediate layers 42-50) (e.g., layers 42 and 44; layers 46 and 48) are welded, stitched, fastened, or adhered together.

[0051] In some embodiments, the plurality of stacked layers (e.g., intermediate layers 42-50) further comprise rubber, carpet, needle punched cotton recycled wool, polyethylene terephthalate, or polypropylene.

[0052] In some embodiments, the plurality of stacked layers (e.g., layers 40-50) further comprise a base layer (e.g., layer 40) adapted to be attached to a seat frame, the base layer (e.g., layer 40) being formed from a material having a higher density than the other layers of the plurality of stacked layers, and can be a high density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or foamed polyvinyl chloride. The base layer can provide a substrate or housing for the intermediate layer and / or comfort layer.

[0053] In some embodiments, the base layer (e.g., layer 40) is formed from an elastomeric material such as a high density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or foamed polyvinyl chloride. The base layer can provide a substrate or housing for the intermediate layer and comfort layer.

[0054] In some embodiments, the base layer (e.g., layer 40) is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane, or foamed polyvinyl chloride. The base layer can provide a substrate or housing for the intermediate layer and comfort layer.

[0055] In some embodiments, the base layer (e.g., layer 40) has a thickness of 2 millimeters or less.

[0056] The techniques described above with respect to method 400 are optionally combined with one or more elements of the methods described hereinafter. For example, this method can be used in conjunction with one or more of methods 1600, 1650, 1680, 2700, 3800.

[0057] A seat assembly (e.g., seat assembly 20), which can be a vehicle seat, an office chair, a personal chair, etc., is described. In some embodiments, the seat assembly (e.g., 20, 120, 210, 310, 410, 520, 620) is manufactured using method 400. The seat assembly includes a substrate (e.g., layer 40) adapted to be attached to a seat frame, and a seat support (e.g., seat supports 36, 38 and / or 54) is stacked on the substrate.

[0058] In some embodiments, the substrate (e.g., layer 40) can be a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the intermediate layer, and the comfort layer may be formed with a contour instead of being formed from a flat sheet. In some embodiments, the substrate is formed from an elastomeric material such as a high-density material such as an elastomer, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or expanded polyvinyl chloride. The base layer can provide a substrate or shell for the intermediate layer and the comfort layer.

[0059] In some embodiments, the substrate (e.g., layer 40) is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane, or expanded polyvinyl chloride.

[0060] In some embodiments, the seat assembly includes a seat frame, a wire suspension mat, a substrate, and / or a panel, which can be a punched steel alloy, a fiber-reinforced polymer, or any suitable structural material, and the substrate (e.g., layer 40) is attached to the seat frame.

[0061] Seat supports that can be seat bottom cushions, seat back cushions, headrests, headrests, bolsters, areas, parts, etc. (e.g., seat supports 36, 38, and / or 54) are described. The seat support (e.g., seat supports 36, 38, and / or 54) can be generally planar within manufacturing tolerances and may or may not have foam, and can be rubber, carpet, needle-punched cotton recycled hair, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, sheets of recycled materials, and / or a plurality of flat layers (e.g., layers 40 - 50) that can each be unrolled from a roll of material. Each of the rolls of material can be a roll of material readily available in the market, such as materials used for vehicle interiors, floor coverings, acoustics, etc. The plurality of flat layers are attached to a seat frame, wire suspension mat, substrate, and / or panel that can be a punched steel alloy, fiber-reinforced polymer, or any suitable structural material, support a passenger on the seat frame, and the plurality of flat layers (e.g., layers 40 - 50) are stacked on top of each other, and the plurality of stacked layers (e.g., layers 40 - 50) differ such that the density continuously increases from the passenger support surface (e.g., layer 50) to the base layer (e.g., 40), thereby providing a transition in density and hardness from the comfortable support at the passenger contact surface in the comfort layer to the structural support in the base layer, which can include high-density materials such as elastomers, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or foamed polyvinyl chloride. The base layer can provide a substrate or housing for the intermediate layer and the comfort layer.

[0062] FIG. 4 shows a seat assembly 120 as a vehicle seat assembly 120 according to some embodiments. Although the vehicle seat assembly 120 is illustrated and described, any seat assembly 120 can be employed. The seat assembly 120 can be utilized in land vehicles, aircraft, ships, etc. The seat assembly 120 can also be utilized as an office chair, a comfort chair, etc.

[0063] The illustrated seat assembly 120 includes a seat bottom cushion 122 that supports the pelvis and thighs of a seated occupant. The seat assembly 120 also includes a seat back cushion 124 that supports the back and shoulders of a seated occupant. A trim cover 126 is provided over the seat cushions 122, 124 to conceal the cushions 122, 124 and to provide a uniform and smooth contact surface for the occupant.

[0064] Figures 5 - 7 show the seat bottom cushion 122 shown in a state removed from the seat assembly 120. The seat bottom cushion 122 has an overall integrated seat cushion 122 design. Such a design has been conventional since seat cushion designs are typically designed in consideration of the final product. Subsequently, modifications are incorporated to support the associated manufacturing process.

[0065] Referring now to FIG. 8, a portion of the seat cushion 122 is partially shown in a state removed from the seat assembly 120. The seat cushion 122 is formed from a plurality of filaments 128 or three - dimensional filament loops of an extruded foamed thermoplastic resin or polymer. The seat cushion 122 is also formed with a base layer 130 joined to and / or integrally formed with the plurality of filaments 128. The extruded mesh - like cushion 122 has a rectangular cross - section or is easily manufactured to have a constant thickness.

[0066] Referring again to FIGS. 5 - 7, the seat cushion 122 is redesigned into three layers, portions or cushion parts 130, 132, 134. The cushion parts 130, 132, 134 are collectively stacked on top of one another to collectively provide the seat cushion 122. The parts 130, 132, 134 are designed to have a common maximum thickness so that the parts 130, 132, 134 can be integrally formed as one sheet of the extruded mesh body 128 and then stacked. In addition, the parts 130, 132, 134 can be pivotally interconnected so as to stack on one another. Referring to FIG. 7, the parallelogram outside the central part 132 is designed to pivot upward to coincide with the outer side surface of the upper part 134.

[0067] FIG. 9 shows a side view of a portion of a cushion 136 according to an embodiment. The cushion 136 includes a pair of cushion parts 138, 140 integrally formed as an integral mesh body 128 of an extruded thermoplastic resin. A pair of recesses 142 are formed on the surface of the foam to define a hinge 144 that pivotally connects the cushion parts 138, 140. As shown in FIG. 10, the cushion parts 138, 140 can be pivoted about the hinge 144. Any number of recesses 142 and any pivoting range can be employed to pivot and / or stack the cushion part 138.

[0068] FIG. 11 shows the seat back cushion 124 shown in a partially removed state. The seat back cushion 124 is formed from an integral sheet of an extruded thermoplastic mesh body 128 having a uniform thickness. The seat back cushion 124 is shown in a state after secondary forming operations such as cutting to incorporate various cushion details. The cutting operation is performed by an automated machine operation such as water jet cutting, laser cutting, die cutting, etc. The seat back cushion 124 includes three cushion parts 146, 148, 150.

[0069] The central portion 146 is the portion facing the front of the seat back cushion 124. The upper portion 148 is the portion facing rearward and is pivotally connected to the central portion 146 along the hinge 152. The lower portion 150 is also the portion facing rearward and is pivotally connected to the central portion 146 along the hinge 154 spaced from the upper hinge 152.

[0070] FIG. 12 shows the rear side of the cushion 124 in the extended orientation. The rear exposed surface is generally flat to facilitate mating the surfaces of the portions 146, 148, 150. As shown from FIG. 12 to FIG. 13, the lower portion 150 is pivoted about the hinge 154 and stacked flat on the rear surface of the central portion 146. From FIG. 13 to FIG. 14, the upper portion 148 is pivoted about the hinge 152 and stacked flat on the rear surface of the central portion 146.

[0071] The portions 146, 148, 150 can then be fixed to each other by heat staking, welding, adhesives, fasteners, surface fasteners, retainers, etc. FIG. 14 shows the rear surface of the assembled seat back cushion 124. Collectively, the portions form a groove 156 for attachment to the seat back frame 158 (FIG. 4). FIG. 15 shows the front surface of the assembled seat back cushion 124.

[0072] The hardness and / or elasticity of each seat cushion 122, 124 is designed by the amount of the portion, material, material density, filament thickness, etc. By giving a common maximum thickness to each portion, a common retainer such as a trim member can be attached to any of the portions. The seat cushions 122, 124 may be directly attached to the seat frame or attached to a foam support layer, a polyurethane carrier, or any other sheet support member.

[0073] FIG. 16 shows a cushion 160 according to another embodiment. Similar to the previous embodiment, the cushion 160 includes a plurality of integrally formed and pivotally interconnected portions 162, 164, 166. A fastening portion 168 is provided along the seam between two of the portions 162, 164. The fastening portion 168 can be a heat staking portion, a welded portion, an adhesive, a surface fastener, a retainer, or the like.

[0074] Seat bottom cushions, seat back cushions, headrests, head supports, bolsters, and seat supports (such as 122, 124, and / or 136) that can be regions and / or portions are described. The seat support (such as 122, 124, and / or 136) is attached to a seat frame, a wire suspension mat, a substrate, and / or a panel that can be a punched and formed steel alloy, a fiber-reinforced polymer, or any suitable structural material, and supports a passenger on the seat frame. It can be an extruded thermoplastic resin mesh, a filament, an extruded foamed thermoplastic resin, or a three-dimensional filament ring of a polymer, and can have a plurality of fused connection portions where two rings are attached to each other. Independently, it includes air in an amount of 60% to 95% by volume, about 0.01 g / cm 3 ~0.200 g / cm 3 and includes a plurality of layers (such as 130, 132, 134, 138, and / or 140), portions, bases, and / or bolsters of an extruded thermoplastic resin mesh having a density of. The plurality of layers (such as 130, 132, 134, 138, and / or 140) are stacked on top of each other and are attached by a retaining clip having an end embedded in the foam and a retaining clip end attached to the plastic mesh base, a hook, a ring connection strip, a hook layer, a ring layer, an adhesive, a hog ring, a single-sided or double-sided retaining clip, joining, welding, sewing, fastening, adhesion, heat staking, and / or retaining.

[0075] In some embodiments, at least one of the plurality of stacked layers (such as 130, 132, 134, 138, and / or 140) has a generally uniform thickness, which can have a rectangular cross-section, a consistent thickness, and / or a parallelogram shape.

[0076] In some embodiments, each of a plurality of stacked layers (e.g., 130, 132, 134, 138 and / or 140) has a generally uniform thickness.

[0077] In some embodiments, the seat support (e.g., 122, 124 and / or 136) further comprises at least two stacked layers (e.g., 130, 132, 134, 138 and / or 140).

[0078] In some embodiments, each of a plurality of stacked layers (e.g., 162, 164 and / or 166) is pivotally connected to each other.

[0079] In some embodiments, at least one recess is formed in one of a plurality of stacked layers (e.g., 162, 164, 166) to provide a pivotal connection.

[0080] In some embodiments, each of a plurality of stacked layers (e.g., 162, 164, 166) is integrally formed or is a single unit.

[0081] A seat assembly (e.g., 120) is described that can be a vehicle seat, an office chair, a personal chair, etc. The seat assembly (e.g., 120) comprises a seat frame and a seat support (e.g., 122, 124 and / or 136) attached to the seat frame.

[0082] Seat bottom cushions, seat back cushions, headrests, head supports, bolsters, and seat supports (e.g., 122, 124, and / or 136) that may be areas and / or portions are described. The seat supports (e.g., 122, 124, and / or 136) are attached to a seat frame, a wire suspension mat, a substrate, and / or a panel that can be a punched and formed steel alloy, a fiber-reinforced polymer, or any suitable structural material, and include a plurality of layers (e.g., 130, 132, 134, 138, and / or 140), portions, bases, and / or bolsters that support a passenger on the seat frame. The plurality of layers (e.g., 130, 132, 134, 138, and / or 140) are stacked on top of each other and can be attached by retention clips having an end embedded in a foam and a retention clip end attached to a plastic mesh base, hook-shaped bodies, and annular-shaped connection strips, hook-shaped layers, annular-shaped layers, adhesives, hog rings, single-sided or double-sided retention clips, joining, welding, sewing, fastening, adhesion, heat caulking, and / or retention. At least one of the plurality of stacked layers (e.g., 162, 164, and / or 166) has a generally uniform thickness, which can have a rectangular cross-section, a consistent thickness, and / or a parallelogram shape. Each of the plurality of stacked layers is integrally and / or integrally formed. Each of the plurality of stacked layers (e.g., 162, 164, and / or 166) is pivotally connected to each other.

[0083] FIG. 16B shows a method 1600 according to some embodiments. The method 1600 is for manufacturing seat bottom cushions, seat back cushions, headrests, head supports, bolsters, and cushions (e.g., cushions 122, 124, 130, 132, 134, 138, and / or 140) that may be areas and / or portions. In various examples, the method 1600 can have more or fewer steps than those described below, and the various steps can be performed in a different order, continuously, or simultaneously.

[0084] A method 1600 of manufacturing a product that can be a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, a region and / or a portion is described. The method 1600 can be an extruded thermoplastic resin mesh, filament, extruded foamed thermoplastic resin or a three-dimensional filament ring of a polymer and / or a plurality of fused connections where two rings are adhered to each other, and independently, 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3 Forming (1602) a plurality of cushion portions (e.g., 130, 132, 134, 138 and / or 140) from an extruded thermoplastic resin mesh having a density of, and stacking (1604) the plurality of cushion portions (e.g., 130, 132, 134, 138 and / or 140) as cushions (e.g., cushions 122, 124 and / or 160).

[0085] In some embodiments, the method 1600 includes forming a plurality of cushion portions (e.g., 130, 132, 134, 138 and / or 140), which can be cutting, die cutting, robotic laser cutting, water jet cutting, laser cutting and / or other flexible automated machine operations.

[0086] In some embodiments, the method 1600 includes forming a plurality of cushion portions (e.g., 162, 164, 166) as an integral sheet.

[0087] In some embodiments, the method 1600 includes folding the cushion portions (e.g., 162, 164, 166) and stacking the cushion portions on top of each other.

[0088] In some embodiments, the method 1600 includes forming at least one recess in at least one of the plurality of cushion portions (e.g., 162, 164, 166) to fold the cushion portions.

[0089] In some embodiments, method 1600 includes cutting a plurality of cushion parts (e.g., 146, 148, 150), which may include die cutting, robotic laser cutting, waterjet cutting, laser cutting, and / or other flexible automated machining operations, to form the plurality of cushion parts.

[0090] Seat bottom cushions, seat back cushions, headrests, head supports, bolsters, seat supports that can be regions and / or parts are described. The seat support is manufactured from any of the techniques described above or below.

[0091] In some embodiments, method 1600 includes installing the product on a seat frame, wire suspension mat, substrate, and / or panel that can be a punched and formed steel alloy, fiber reinforced polymer, or any suitable structural material.

[0092] A seat assembly that can be a vehicle seat, office chair, personal chair, etc. is described. The seat assembly is manufactured by any of the methods of the techniques described above or below.

[0093] The techniques described above with respect to method 1600 are optionally combined with one or more elements of the methods described above and / or below. For example, this method can be used with one or more of methods 400, 1650, 1680, 2700, 3800.

[0094] FIG. 16C shows method 1650 according to some embodiments. Method 1650 is for manufacturing seat bottom cushions, seat back cushions, headrests, head supports, bolsters, cushions (e.g., cushions 122, 124, 130, 132, 134, 138, and / or 140) that can be regions and / or parts. In various examples, method 1650 can have more or fewer steps than those described below, and the various steps can be performed in a different order, continuously, or simultaneously.

[0095] Method 1650 is for designing a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, and a seat cushion that can be an area and / or a portion. Method 1650 includes obtaining (1652) a design of an integral seat cushion (e.g., integral seat cushion 122), and redesigning the integral seat cushion design into a plurality of stacked cushion part designs (e.g., 130, 132, and / or 134), layers, parts, bases, and / or bolsters (1654).

[0096] In some embodiments, Method 1650 includes redesigning an integral seat cushion design into a plurality of stacked cushion part designs, each having a common maximum thickness.

[0097] The techniques described above with respect to Method 1650 are optionally combined with one or more elements of the methods described above and / or below. For example, this method can be used with Methods 400, 1600, 1680, 2700, 3800.

[0098] FIG. 16D shows Method 1680 according to some embodiments. Method 1680 is for manufacturing a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, and a seat cushion that can be an area and / or a portion (e.g., cushions 122, 124, 130, 132, 134, 138, and / or 140). In various examples, Method 1680 can have more or fewer steps than those described below, and the various steps can be performed in a different order, continuously, or simultaneously.

[0099] Method 1680 includes designing a plurality of cushion part designs according to either a preceding or a subsequent technique (1682), and making a three-dimensional filament ring of an extruded thermoplastic resin mesh, filament, extruded foamed thermoplastic resin, or polymer, with a plurality of fused connections where two rings are attached to each other, and independently, 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3Forming a plurality of cushion portions from an extruded thermoplastic resin network including the density thereof (1684).

[0100] In some embodiments, method 1680 includes stacking a plurality of cushion portions as seat bottom cushions, seat back cushions, headrests, head supports, bolsters, regions and / or cushions that can be portions.

[0101] The techniques described above with respect to method 1680 are optionally combined with one or more elements of the methods described above and / or below. For example, this method can be used with one or more of methods 400, 1600, 1650, 2700, 3800.

[0102] Referring to FIG. 17, a perspective view of a vehicle seat 210 having an extruded plastic network base plastic with a network bolster is shown. The vehicle seat 210 includes a seat back 212 and a seat bottom 214. The seat back 212 includes a right seat back bolster 216 and a left seat back bolster 218. The seat bottom 214 includes a right seat bottom bolster 220 and a left seat bottom bolster 222.

[0103] Figures 18A and 18B show cross-sections of a seat support as a vehicle seat cushion component 230. Advantageously, the vehicle seat cushion component 230 can be part of the vehicle seat back 212 or the vehicle seat bottom 214. The vehicle seat component 230 includes a layer as a plastic mesh base 232. The plastic mesh base 232 has a first edge 234, a second edge 236, a first surface 238, and a second surface 240. The first plastic mesh bolster 242 is another layer attached to the plastic mesh base 232 at the first edge 234. The second plastic mesh bolster 244 is another layer attached to the plastic mesh base 232 at the second edge 236. The first plastic mesh bolster 242 includes a first plurality of three-dimensional filament loops 250 or filaments made of a first thermoplastic resin or polymer. The second plastic mesh bolster 244 includes a second plurality of three-dimensional filament loops 252 or filaments made of a second thermoplastic polymer. The first plurality of three-dimensional filament loops 250 and the second plurality of three-dimensional filament loops 252 are each independently formed into a shape suitable for the vehicle seat bolsters 242, 244. The dotted lines around these components emphasize the shapes of these bolster components. Similarly, the plastic mesh base 232 includes a third plurality of three-dimensional filament loops 254 made of a third thermoplastic polymer. The third plurality of three-dimensional filament loops 254 are generally formed into a block shape or any shape suitable for functioning as a cushion. Figure 18A shows an improved form in which the first plastic mesh bolster 242 is attached to the first edge 234 and the second plastic mesh bolster 244 is attached to the second edge 236, and Figure 18B shows an improved form in which the first plastic mesh bolster 242 and the second plastic mesh bolster 244 are each disposed on the first surface 238.

[0104] Figures 19A and 19B show cross-sections of another deformed form of the vehicle seat cushion part 230. As described above, the vehicle seat cushion part 230 can be part of the vehicle seat back 212 or the vehicle seat bottom 214. The vehicle seat part 230 includes a plastic mesh-like base 232. The plastic mesh-like base 232 has a first edge 234, a second edge 236, a first surface 238, and a second surface 240. The first plastic mesh-like bolster 242 is attached to the plastic mesh-like base 232 at the first edge 234. The second plastic mesh-like bolster 244 is attached to the plastic mesh-like base 232 at the second edge 236. The first plastic mesh-like bolster 242 includes a first plurality of three-dimensional filament ring bodies 250 made of a first thermoplastic polymer. The second plastic mesh-like bolster 244 includes a second plurality of three-dimensional filament ring bodies 252 made of a second thermoplastic polymer. The first plurality of three-dimensional filament ring bodies 250 and the second plurality of three-dimensional filament ring bodies 252 are each independently formed into a shape suitable for the vehicle seat bolsters 242, 244. The dotted lines around these parts emphasize the shapes of these bolster parts. Similarly, the plastic mesh-like base 232 includes a third plurality of three-dimensional filament ring bodies 254 made of a third thermoplastic polymer. The third plurality of three-dimensional filament ring bodies 254 are generally formed into a block shape or any shape suitable for functioning as a cushion. An optional skin layer 256 is disposed on and in contact with the first surface 238 of the formed plurality of three-dimensional filament ring bodies 254. The vehicle seat part 230 can include one or both of the skin layers 256 and 258.

[0105] Referring to FIGS. 18A, 18B, 19A and 19B, a first plastic mesh bolster 242 is attached to a plastic mesh base 232, and a second plastic mesh bolster 244 is attached to the plastic mesh base 232. These attachment portions 260 and 262 can be any attachment mechanism known to those skilled in the art, such as Velcro (registered trademark) connection strips (hook layer and loop layer), adhesives, hog rings, single-sided or double-sided retaining clips, etc.

[0106] Examples of methods for forming a first plurality of three-dimensional filament loops, a second plurality of three-dimensional filament loops, and a third plurality of three-dimensional filament loops and their properties are disclosed in U.S. Patent No. 10,233,073 and U.S. Patent No. 9,918,559, and by this reference, the entire disclosure of these is incorporated herein.

[0107] Referring to FIGS. 18A, 18B, 19A and 19B, independently, at least a subset of the loops within the first plurality of three-dimensional filament loops 250, at least a subset of the loops within the second plurality of three-dimensional filament loops 252, and at least a subset of the loops within the third plurality of three-dimensional filament loops 254 are not parallel to each other or not aligned. In one improved form, independently, at least a subset of the loops within the first plurality of three-dimensional filament loops 250, at least a subset of the loops within the second plurality of three-dimensional filament loops 252, and at least a subset of the loops within the third plurality of three-dimensional filament loops 254 are randomly oriented.

[0108] In one variant form, the first plastic mesh bolster 242, the second plastic mesh bolster 244, and the plastic mesh base 232 each independently contain 60% to 95% by volume of air. In some improved forms, the first plastic mesh bolster 242, the second plastic mesh bolster 244, and the plastic mesh base 232 each independently contain, at least, in ascending order of preference, 60%, 65%, 70%, 75% or 80% by volume of air, and at most, in ascending order of preference, 95%, 93%, 90%, 85% or 80% by volume of air. In one improved form, the first plastic mesh bolster 242, the second plastic mesh bolster 244, and the plastic mesh base 232 each independently have a density of about 0.01 g / cm 3 ~0.200 g / cm 3 . In some improved forms, the plurality of three-dimensional filament rings include a plurality of fused connections 264 where two rings are adhered to each other.

[0109] In one variant form, the three-dimensional filament ring 250, the three-dimensional filament ring 252, and the three-dimensional filament ring 254, and any optional skin layer that may be present, each independently are composed of a thermoplastic polymer. In one improved form, the three-dimensional filament ring is an extruded thermoplastic polymer. 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 one improved form, the thermoplastic polymer includes linear low-density polyethylene. In some improved forms, the three-dimensional filament ring has a fineness of 200 to 10,000 decitex. In one improved form, the three-dimensional filament ring has a fineness of 200 to 5,000 decitex. In a further improved form, the three-dimensional filament ring has a fineness of 200 to 3,000 decitex.

[0110] A vehicle seat cushion (e.g., vehicle seat cushion component 230) that can be a seat bottom cushion, a seat back cushion, a headrest, a headrest, a bolster, a region and / or a part is described. The vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a first plastic mesh bolster (e.g., first plastic mesh bolster 242) formed by compression molding and including a first plurality of three-dimensional filament annular bodies (e.g., annular body 250). At least a subset of the annular bodies within the first plurality of three-dimensional filament annular bodies may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The first plurality of three-dimensional filament annular bodies are composed of a first thermoplastic polymer that can have a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3 and are each independently formed in the form of a vehicle seat bolster and can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a second plastic mesh bolster (e.g., second plastic mesh bolster 244) formed by compression molding and including a second plurality of three-dimensional filament annular bodies (e.g., annular body 252). At least a subset of the annular bodies within the second plurality of three-dimensional filament annular bodies may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The second plurality of three-dimensional filament annular bodies are composed of a first thermoplastic polymer that can have a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3It is composed of a second thermoplastic polymer that can have a density of, and each is independently formed into the shape of a vehicle seat bolster and can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The vehicle seat cushion (e.g., vehicle seat cushion component 230) includes a plastic mesh base (e.g., plastic mesh base 232), and the plastic mesh base can be an extruded thermoplastic resin mesh, a filament, an extruded foamed thermoplastic resin, or a three-dimensional filament ring of a polymer, and can have a plurality of fusion connection parts where two rings are attached to each other. Independently, it can contain 60 volume percent to 95 volume percent of air, about 0.01 g / cm 3 ~0.200 g / cm 3 of density, includes a third plurality of three-dimensional filament rings (e.g., ring 254), and at least a subset of the rings within the third plurality of three-dimensional filament rings may or may not be parallel to each other or aligned, and may be randomly oriented, and can have a fineness of 200 decitex to 10,000 decitex. The third plurality of three-dimensional filament rings contain 60 volume percent to 95 volume percent of air, about 0.01 g / cm 3 ~0.200 g / cm 3Composed of a third thermoplastic polymer that can be of a density, each of which is independently formed into the shape of a vehicle seat bolster and can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The plastic mesh base may have a block shape and has a first edge (e.g., the first edge 234), a second edge (e.g., the second edge 236), a first surface (e.g., the first surface 238), and a second surface (e.g., the second surface 240). The first plastic mesh bolster (e.g., the first plastic mesh bolster 242) is attached to the plastic mesh base (e.g., the plastic mesh base 232) at the first edge (e.g., the first edge 234), and the second plastic mesh bolster (e.g., the second plastic mesh bolster 244) is attached to the plastic mesh base (e.g., the plastic mesh base 232) at the first edge (e.g., the first edge 234). The attachment part can be by a retaining clip having an end embedded in the foam and a retaining clip end attached to the plastic mesh base, a hook-shaped body and an annular connecting strip, a hook-shaped layer, an annular layer, an adhesive, a hog ring, a single-sided or double-sided retaining clip, bonding, welding, sewing, fastening, adhesion, heat caulking, and / or other types of retention.

[0111] In some embodiments, the vehicle seat cushion component (e.g., the vehicle seat cushion component 230) is included in the vehicle seat back (e.g., the vehicle seat back 212) or the vehicle seat bottom (e.g., the vehicle seat bottom 214).

[0112] In some embodiments, the first plurality of three-dimensional filament annular bodies (e.g., the annular body 250), the second plurality of three-dimensional filament annular bodies (e.g., the annular body 252), and the third plurality of three-dimensional filament annular bodies each independently include a plurality of fusion connection parts where two annular bodies are attached to each other.

[0113] In some embodiments, the first plurality of three-dimensional filament annular bodies (e.g., annular body 250) and the second plurality of three-dimensional filament annular bodies (e.g., annular body 252) are each independently formed in the form of a vehicle seat bolster.

[0114] In some embodiments, the first plastic mesh bolster (e.g., the first plastic mesh bolster 242) and the second plastic mesh bolster are each disposed on the first surface.

[0115] In some embodiments, the first plastic mesh bolster (e.g., the first plastic mesh bolster 242) is attached to the first edge, and the second plastic mesh bolster is attached to the second edge.

[0116] In some embodiments, the first plastic mesh bolster (e.g., the first plastic mesh bolster 242) and the second plastic mesh bolster are attached to the plastic mesh base (e.g., the plastic mesh base 232) by means of a surface strip, an adhesive, a retaining clip and / or a hog ring.

[0117] In some embodiments, at least a subset of the annular bodies within the first plurality of three-dimensional filament annular bodies (e.g., annular body 250), at least a subset of the annular bodies within the second plurality of three-dimensional filament annular bodies (e.g., annular body 252), and at least a subset of the annular bodies within the third plurality of three-dimensional filament annular bodies are not parallel to each other or not aligned.

[0118] In some embodiments, at least a subset of the annular bodies within the first plurality of three-dimensional filament annular bodies (e.g., annular body 250), at least a subset of the annular bodies within the second plurality of three-dimensional filament annular bodies (e.g., annular body 252), and at least a subset of the annular bodies within the third plurality of three-dimensional filament annular bodies are randomly oriented.

[0119] In some embodiments, the first epidermal layer is disposed on the first surface of a plastic reticulate base (e.g., plastic reticulate base 232).

[0120] In some embodiments, the first epidermal layer is disposed on the second surface of a plastic reticulate base (e.g., plastic reticulate base 232).

[0121] In some embodiments, the first plastic reticulate bolster (e.g., first plastic reticulate bolster 242), the first plastic reticulate bolster and the plastic reticulate base (e.g., plastic reticulate base 232) each independently contain 60 volume percent to 95 volume percent air.

[0122] In some embodiments, the first plastic reticulate bolster (e.g., first plastic reticulate bolster 242), the first plastic reticulate bolster and the plastic reticulate base each independently have a density of about 0.01 g / cm 3 ~0.200 g / cm 3 .

[0123] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extruded thermoplastic polymer.

[0124] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0125] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently linear low density polyethylene.

[0126] In some embodiments, the first plurality of three-dimensional filament annular bodies (e.g., annular body 250), the second plurality of three-dimensional filament annular bodies (e.g., annular body 252), and the third plurality of three-dimensional filament annular bodies have a fineness of 200 decitex to 10,000 decitex.

[0127] Seat bottom cushions, seat back cushions, headrests, headrests, bolsters, vehicle seat cushion parts (e.g., 230) that can be regions and / or portions are described. The vehicle seat cushion part (e.g., 230) includes a first plastic mesh-like bolster (e.g., 242) that can be formed by compression molding and includes a first plurality of three-dimensional filament annular bodies (e.g., 250). At least a subset of the annular bodies within the first plurality of three-dimensional filament annular bodies may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The first plurality of three-dimensional filament annular bodies are composed of a first thermoplastic polymer that can have a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3 and are each independently formed in the form of a vehicle seat bolster and can be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The vehicle seat cushion part (e.g., 230) includes a second plastic mesh-like bolster (e.g., 244) that can be formed by compression molding and includes a second plurality of three-dimensional filament annular bodies (e.g., 252). At least a subset of the annular bodies within the second plurality of three-dimensional filament annular bodies may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The second plurality of three-dimensional filament annular bodies are composed of a first thermoplastic polymer that can have a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm3 ~0.200 g / cm 3 and is composed of a second thermoplastic polymer that can have a density of ~0.200 g / cm. Each is independently formed in the form of a vehicle seat bolster and can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The vehicle seat cushion part (e.g., 230) includes a plastic mesh-like base (e.g., 232), and the plastic mesh-like base can be an extruded thermoplastic resin mesh, a filament, an extruded foamed thermoplastic resin, or a three-dimensional filament ring of a polymer, and can have a plurality of fusion connection parts where two rings are attached to each other. Independently, it contains 60 volume percent to 95 volume percent air and has a density of about 0.01 g / cm 3 ~0.200 g / cm 3 and includes a third plurality of three-dimensional filament rings (e.g., 254). At least a subset of the rings within the third plurality of three-dimensional filament rings may or may not be parallel to each other or aligned, and may be randomly oriented, and can have a fineness of 200 decitex to 10,000 decitex. The third plurality of three-dimensional filament rings contains 60 volume percent to 95 volume percent air and has a density of about 0.01 g / cm 3 ~0.200 g / cm 3It is composed of a third thermoplastic polymer that can be of a density, and each is independently formed into the shape of a vehicle seat bolster, and can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a linear low-density polyethylene. The plastic mesh base (e.g., 232) has a first edge, a second edge, a first surface, and a second surface. The first plastic mesh bolster (e.g., 242) is attached to the plastic mesh base (e.g., 232) at the first edge, and the second plastic mesh bolster is attached to the plastic mesh base at the first edge. The attachment part can be a retaining clip having an end embedded in the foam and a retaining clip end attached to the plastic mesh base, a hook-shaped body and an annular connection strip, a hook-shaped layer, an annular layer, an adhesive, a hog ring, a single-sided or double-sided retaining clip, a coupling, a welding, a sewing, a fastening, an adhesion, a heat caulking, and / or other means of retention. The first plurality of three-dimensional filament annular bodies (e.g., 250), the second plurality of three-dimensional filament annular bodies (e.g., 252), and the third plurality of three-dimensional filament annular bodies (e.g., 254) each independently include a plurality of fusion connection parts where two annular bodies are attached to each other.

[0128] In some embodiments, the vehicle seat cushion component (e.g., 230) is included in the vehicle seat back or the vehicle seat bottom.

[0129] In some embodiments, the plastic mesh base (e.g., 232) is 60 volume percent to 95 volume percent air.

[0130] In some embodiments, the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0131] The above techniques are optionally combined with one or more elements of the methods described above / below. For example, these parts can be used together with one or more of the methods 400, 1600, 1650, 1680, 2700, 3800.

[0132] Referring to FIG. 20, a perspective view of a vehicle seat 310 having an extruded plastic mesh base is shown. The vehicle seat 310 includes a seat back 312 and a seat bottom 314. The seat back 312 includes a right seat back bolster 316 and a left seat back bolster 318. The seat bottom 314 includes a right seat bottom bolster 320 and a left seat bottom bolster 322. The seat back 312 also includes a seat back frame 324 for attaching seat back cushion components. Similarly, the seat bottom 314 includes a seat bottom frame 326 for attaching seat bottom cushion components.

[0133] Referring to FIGS. 21A and 21B, a schematic view of a vehicle seat component 330 is shown. The vehicle seat component 330 includes a first bolster assembly 332. The first bolster assembly 332 includes a first core cushion portion 334, layer or part surrounded by a first outer bolster cover 336 of a first non-woven material. A first bolster trim cover 338 surrounds the first outer bolster cover 336. The second bolster assembly 340 includes a second core cushion portion 342, layer or part surrounded by a second outer bolster cover 344 of a second non-woven material. A second bolster trim cover 348 surrounds the second outer bolster cover 344. The trim cover portion 350 includes a first edge 352 and a second edge 354. Characteristically, the first bolster assembly 332 is sewn to the trim cover portion at the first edge at the sewing line 356. Similarly, the second bolster assembly 340 is sewn to the trim cover portion at the second edge at the sewing line 358. In one variant, the vehicle seat component 330 further includes a central cushion component 360 positioned within an opening 362 defined by the trim cover portion.

[0134] In one modified form, the first outer bolster cover 336 and the second outer bolster cover 344 each independently include a non-woven fabric or a woven fabric. For example, the first outer bolster cover 336 and the second outer bolster cover 344 each independently include natural fibers (e.g., jute fibers).

[0135] In one variant form, the first bolster assembly 332 and the second bolster assembly 340 are each independently manufactured by compression molding. For example, a layered / sandwich assembly of jute or non-woven material and a core cushion portion can be formed by compression molding. In one modified form, each bolster assembly includes an upper layer of jute / non-woven fabric, an intermediate cushion portion, and a lower layer of jute / non-woven fabric.

[0136] In one variant form, the trim cover portion defines an opening 362 for accommodating the central cushion component 360.

[0137] In one variant form, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 are each independently composed of a foamed polymer. In one modified form, the first core cushion portion 334 and the second core cushion portion 342 are each independently composed of foamed polyurethane. As is known in the art, foamed polyurethane is formed from the reaction of isocyanate, polyol, and a suitable foaming agent.

[0138] In another variant form shown in FIGS. 21A and 21B, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 are each independently composed of a plurality of three-dimensional filament rings or filaments composed of a thermoplastic polymer or resin. In one modified form, at least a subset of the rings within the plurality of three-dimensional filament rings are not parallel to each other or not aligned. In one modified form, the rings within the plurality of three-dimensional filament rings are randomly oriented.

[0139] Referring further to FIGS. 21A and 21B, in another variant, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 each independently include a plurality of three-dimensional filamentary annular bodies having 60 to 95 volume percent air. In some improved forms, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 each independently include at least, in ascending order of preference, 60 volume percent, 65 volume percent, 70 volume percent, 75 volume percent, or 80 volume percent air, and at most, in ascending order of preference, 95 volume percent, 93 volume percent, 90 volume percent, 85 volume percent, or 80 volume percent air, of a plurality of three-dimensional filamentary annular bodies. In one improved form, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 independently have a density of about 0.01 g / cm 3 to 0.200 g / cm 3 and include a plurality of three-dimensional filamentary annular bodies. In some improved forms, the plurality of three-dimensional filamentary annular bodies include a plurality of fused connections 364 where two annular bodies are adhered to each other.

[0140] In one improved form, the three-dimensional filamentary annular body is an extruded thermoplastic polymer. 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 one improved form, the thermoplastic polymer includes linear low-density polyethylene. In another improved form, the thermoplastic polymer is a biodegradable or recyclable polymer (e.g., a "green" polymer).

[0141] In some improved forms, the three-dimensional filament ring has a fineness of 200 decitex to 10,000 decitex. In one improved form, the three-dimensional filament ring has a fineness of 200 decitex to 5,000 decitex. In yet another improved form, the three-dimensional filament ring has a fineness of 200 decitex to 3,000 decitex.

[0142] Examples of methods for forming a plurality of three-dimensional filament rings and their characteristics are disclosed in U.S. Patent No. 10,233,073 and U.S. Patent No. 9,918,559, and by this reference, the entire disclosures of these are incorporated herein.

[0143] Advantageously, the vehicle seat cushion component 330 described above improves the sustainability of current vehicle seat components, provides support to passengers, and improves the tactile feel and (sound and energy related) damping quality of the extruded plastic mesh assembly. In particular, the vehicle seat cushion component 330 provides sound damping to the rattling mesh material where any sound that may be added to the assembly occurs, enables positive profiling and shaping with respect to the A-side features, enables multiple densities according to the layer configuration (the upper and bottom can have separate densities according to temperature), temperature buffering (thermal insulation characteristics), and a consistent tactile feel.

[0144] Referring to FIGS. 20, 21A and 21B, a vehicle seat 310 including the above-described vehicle seat cushion component 330 is shown. The vehicle seat 310 includes a seat bottom 314 having a seat bottom frame 326 and a seat back 312 attached to the seat bottom 314. The seat back 312 includes a seat back frame 324. The vehicle seat cushion component 330 is attached to the seat back frame 324 and / or the bottom frame 326. As described above, the vehicle seat cushion component 330 includes a first bolster assembly 332. The first bolster assembly 332 includes a first core cushion portion 334 surrounded by a first outer bolster cover 336 of a first non-woven material. A first bolster trim cover 338 surrounds the first outer bolster cover 336. The second bolster assembly 340 includes a second core cushion portion 342 surrounded by a second outer bolster cover 344 of a second non-woven material. A second bolster trim cover 348 surrounds the second outer bolster cover 344. The trim cover portion 350 includes a first edge 352 and a second edge 354. Characteristically, the first bolster assembly 332 is sewn to the trim cover portion at the first edge 352 at a sewing line 356. Similarly, the second bolster assembly 340 is sewn to the trim cover portion at the second edge 354 at a sewing line 358. In one variant, the vehicle seat component 330 further includes a central cushion component 360 positioned within an opening 362 defined by the trim cover portion 350.

[0145] Vehicle seat cushion components (e.g., 330) that can be seat bottom cushions, seat back cushions, headrests, head supports, bolsters, regions and / or portions are described. The vehicle seat cushion component (e.g., 330) is a first bolster assembly (e.g., 332) that can be formed by compression molding and includes a first core cushion portion (e.g., 334), the first core cushion portion can be foamed polyurethane and is composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer, and is air at 60% to 95% by volume, about 0.01 g / cm3 ~0.200 g / cm 3 and having a density of ~0.200 g / cm, and is surrounded by a first outer bolster cover (e.g., 336) which can be a non-woven fabric, natural fiber, and / or jute fiber. The first outer bolster cover is surrounded by a first bolster trim cover (e.g., 338) which can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials. A first bolster assembly, and a second bolster assembly (e.g., 340) which can be formed by compression molding and includes a second core cushion portion (e.g., 342). The second core cushion portion can be made of foamed polyurethane and is composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer, and is 60% to 95% air by volume and has a density of about 0.01 g / cm 3 ~0.200 g / cm 3 and having a density of ~0.200 g / cm, and is surrounded by a second outer bolster cover (e.g., 344) which can be a non-woven fabric, natural fiber, and / or jute fiber. A second bolster assembly, and a trim cover portion (e.g., 350) which can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials and has a first edge and a second edge. The first bolster assembly (e.g., 332) is sewn to the trim cover portion (e.g., 350) at the first edge, and the second bolster assembly (e.g., 340) is sewn to the trim cover portion (e.g., 350) at the second edge.

[0146] In some embodiments, the vehicle seat cushion component (e.g., 330) is included in a vehicle seat back or a vehicle seat bottom.

[0147] In some embodiments, the first bolster assembly (e.g., 332) and the second bolster assembly (e.g., 340) are each independently formed by compression molding and are a layered / sandwich assembly of a chute or non-woven material and a core cushion portion, such as an upper chute / non-woven fabric, an intermediate cushion portion, and a lower chute / non-woven fabric.

[0148] In some embodiments, the first outer bolster cover (e.g., 336) and the second outer bolster cover (e.g., 344) each independently include a non-woven fabric.

[0149] In some embodiments, the first outer bolster cover (e.g., 336) and the second outer bolster cover (e.g., 344) each independently include natural fibers.

[0150] In some embodiments, the vehicle seat cushion component (e.g., 330) further includes a central cushion component (e.g., 360), which may be made of foamed polyurethane, composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer, is 60 volume percent to 95 volume percent air and / or has a density of about 0.01 g / cm 3 ~0.200 g / cm 3 and can be positioned within an opening defined by a trim cover portion.

[0151] In some embodiments, the first core cushion portion (e.g., 334), the second core cushion portion (e.g., 342), and the central cushion component (e.g., 360) are each independently composed of foamed polyurethane such as isocyanate, polyol, and a suitable blowing agent.

[0152] In some embodiments, the first core cushioning portion (e.g., 334), the second core cushioning portion (e.g., 342), and the central cushioning component (e.g., 360) are each independently composed of a plurality of three-dimensional filament rings, and the plurality of three-dimensional filament rings can be a plurality of fusion connection portions where two rings are adhered to each other, not parallel or aligned with each other, having a fineness of 200 decitex to 10,000 decitex, and may be composed of a thermoplastic polymer, and the thermoplastic polymer can be a polyolefin, a styrenic thermoplastic elastomer, a polyester thermoplastic elastomer, a polyurethane thermoplastic elastomer, a polyamide thermoplastic elastomer, and / or a biodegradable or recyclable polymer.

[0153] In some embodiments, the plurality of three-dimensional filament rings include a plurality of fusion connection portions where two rings are adhered to each other.

[0154] In some embodiments, at least a subset of the rings within the plurality of three-dimensional filament rings are not parallel or aligned with each other.

[0155] In some embodiments, the first core cushioning portion (e.g., 334), the second core cushioning portion (e.g., 342), and the central cushioning component (e.g., 360) are independently 60 volume percent to 95 volume percent air.

[0156] In some embodiments, the first core cushioning portion (e.g., 334), the second core cushioning portion (e.g., 342), and the central cushioning component (e.g., 360) are each independently about 0.01 g / cm 3 ~0.200 g / cm 3 and have a density of.

[0157] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0158] In some embodiments, the thermoplastic polymer is composed of components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0159] In some embodiments, the thermoplastic polymer is a biodegradable or recyclable polymer.

[0160] In some embodiments, the plurality of three-dimensional filament rings have a fineness of 200 decitex to 10,000 decitex.

[0161] In some embodiments, the vehicle seat cushion component (e.g., 330) includes providing sound insulation and temperature buffering.

[0162] A vehicle seat (e.g., 310), which can be a vehicle seat such as a vehicle seat, an office chair, a personal chair, etc., is disclosed. The vehicle seat (e.g., 310) has a seat bottom having a seat bottom frame, a wire suspension mat, a base material, and / or a panel, which can be a punched steel alloy, a fiber-reinforced polymer, or any suitable structural material, and a seat back attached to the seat bottom having a seat back frame, a wire suspension mat, a base material, and / or a panel, which can be a punched steel alloy, a fiber-reinforced polymer, or any suitable structural material, and vehicle seat cushion components (e.g., 330), which can be a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, a region, and / or a portion, attached to the seat bottom frame and / or the seat back frame. The vehicle seat cushion component (e.g., 330) can be formed by compression molding and is a first bolster assembly (e.g., 332) including a first core cushion portion (e.g., 334). The first core cushion portion can be a foamed polyurethane and is composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer, and is 60 volume percent to 95 volume percent air and about 0.01 g / cm 3 ~0.200 g / cm 3a density of, and is surrounded by a first outer bolster cover (e.g., 336) that can be a non-woven fabric, natural fiber, and / or jute fiber. The first outer bolster cover is surrounded by a first bolster trim cover (e.g., 338) that can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials. The first bolster assembly, and a second bolster assembly (e.g., 340) that can be formed by compression molding and includes a second core cushion portion (e.g., 342). The second core cushion portion can be a foamed polyurethane and is composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer and is 60% to 95% air by volume and has a density of about 0.01 g / cm 3 ~0.200 g / cm 3 a density of, and is surrounded by a second outer bolster cover (e.g., 344) that can be a non-woven fabric, natural fiber, and / or jute fiber. The second outer bolster cover is surrounded by a second bolster trim cover that can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials. The second bolster assembly, and a trim cover portion that can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials and has a first edge and a second edge. The first bolster assembly (e.g., 332) is sewn to the trim cover portion at the first edge, and the second bolster assembly (e.g., 340) is sewn to the trim cover portion at the second edge.

[0163] In some embodiments, the first outer bolster cover (e.g., 336) and the second outer bolster cover (e.g., 344) each independently include a non-woven fabric.

[0164] In some embodiments, the first outer bolster cover (e.g., 336) and the second outer bolster cover (e.g., 344) each independently include natural fibers.

[0165] In some embodiments, the vehicle seat cushion component (e.g., 330) further includes a central cushion component (e.g., 360), the central cushion component may be made of foamed polyurethane, and is composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer, is 60% to 95% by volume of air and / or about 0.01 g / cm 3 ~0.200 g / cm 3 of density, and may be positioned within an opening defined by the trim cover portion.

[0166] In some embodiments, the first core cushion portion (e.g., 334), the second core cushion portion (e.g., 342), and the central cushion component (e.g., 360) are each independently composed of foamed polyurethane such as isocyanate, polyol, and a suitable foaming agent.

[0167] In some embodiments, the first core cushion portion (e.g., 334), the second core cushion portion (e.g., 342), and the central cushion component (e.g., 360) are each independently composed of a plurality of three-dimensional filament annular bodies. The plurality of three-dimensional filament annular bodies can be a plurality of fused connection portions where two annular bodies are attached to each other, are not parallel or aligned with each other, have a fineness of 200 decitex to 10,000 decitex, and may be composed of a thermoplastic polymer. The thermoplastic polymer can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a biodegradable or recyclable polymer.

[0168] In some embodiments, the plurality of three-dimensional filament annular bodies include a plurality of fused connection portions where two annular bodies are attached to each other.

[0169] In some embodiments, at least a subset of the annuli within the plurality of three-dimensional filament annuli are not parallel or aligned with each other.

[0170] In some embodiments, the first core cushion portion (e.g., 334) and the second core cushion portion (e.g., 342) are 60 volume percent to 95 volume percent air.

[0171] In some embodiments, the first core cushion portion (e.g., 334) and the second core cushion portion (e.g., 342) are each independently about 0.01 g / cm 3 ~0.200 g / cm 3 and have a density of.

[0172] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer, and the extruded thermoplastic polymer can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or a biodegradable or recyclable polymer.

[0173] The techniques described above are optionally combined with one or more elements of the methods described above / hereinafter. For example, these parts can be used with one or more of the methods 400, 1600, 1650, 1680, 2700, 3800.

[0174] Referring to FIG. 22, a perspective view of a vehicle seat 410 having an extruded plastic mesh-like base is shown. The vehicle seat 410 includes a seat back 412 and a seat bottom 414. The seat back 412 includes a right seat back bolster 416 and a left seat back bolster 418. The seat bottom 414 includes a right seat bottom bolster 420 and a left seat bottom bolster 422.

[0175] Figures 23A and 23B show cross-sections of the vehicle seat part 430. Advantageously, the vehicle seat part 430 is a vehicle seat back or a vehicle seat bottom. The vehicle seat part 430 comprises a plastic mesh-like base 432. The plastic mesh-like base 432 comprises a plurality 434 of three-dimensional filament rings or filaments formed from a thermoplastic polymer or resin. In this context, the plurality 434 of three-dimensional filament rings have generally any shape suitable for functioning as a block shape or a cushion. The plastic mesh-like base 432 has a first edge 442, a second edge 444, a first face 446 and a second face 448. A first foam bolster 450 is attached to the plastic mesh-like base at the first edge 442. A second foam bolster 452 is attached to the plastic mesh-like base 432 at the second edge 444. Figure 23A shows one improvement form in which the first foam bolster 450 is attached to the first edge 442 and the second foam bolster 452 is attached to the second edge 444, and Figure 23B shows one improvement form in which the first foam bolster 450 and the second foam bolster 452 are each disposed on the first face 446.

[0176] Figs. 24A and 24B show cross-sections of another variant form of the cushion portion of a vehicle seat. As described above, the vehicle seat component 430 is either the vehicle seat back or the vehicle seat bottom. The vehicle seat component 430 includes a plastic mesh-like base 432. The plastic mesh-like base 432 includes a plurality of molded three-dimensional filament rings 434 or filaments made of a thermoplastic polymer or resin. The plastic mesh-like base 432 has a first edge 442, a second edge 444, a first surface 446, and a second surface 448. A first foam bolster 450 is attached to the plastic mesh-like base 432 at the first edge 442. A second foam bolster 452 is attached to the plastic mesh-like base 432 at the second edge 444. In this variant form, an optional skin layer 456 is disposed on and in contact with the first surface 446 of the plurality of molded three-dimensional filament rings 434. The optional skin layer 456 is disposed on and in contact with the first surface 446 of the plurality of molded three-dimensional filament rings. The vehicle seat component 430 can include one or both of the skin layers 456 and 458.

[0177] Referring to Figs. 23A, 23B, 24A, and 24B, the first foam bolster 450 and the second foam bolster 452 are each independently composed of a foam polymer. In one improved form, the first foam bolster 450 and the second foam bolster 452 are each independently composed of a foam polyurethane. As is known in the art, foam polyurethane is formed from the reaction of an isocyanate, a polyol, and a suitable blowing agent.

[0178] Referring to FIGS. 23A, 23B, 24A and 24B, the first foam bolster 450 is attached to the plastic mesh base 432 by the first retaining clip 460, and the second foam bolster 452 is attached to the plastic mesh base 432 by the second retaining clip 462. The first retaining clip 460 and the second retaining clip 462 each independently have an end embedded in the foam and a retaining clip end attached to the plastic mesh base. Examples of retaining clips are disclosed in U.S. Patent Application No. 17 / 724,866, filed Apr. 20, 2022, the disclosure of which is hereby incorporated by reference in its entirety.

[0179] Examples of methods of forming a plurality of three-dimensional filament loops and their properties are disclosed in U.S. Patent No. 10,233,073 and U.S. Patent No. 9,918,559, the disclosures of which are hereby incorporated by reference in their entirety.

[0180] Referring to FIGS. 23A, 23B, 24A and 24B, at least a subset of the loops within the plurality of three-dimensional filament loops are not parallel or aligned with each other. In one improvement, the loops within the plurality of three-dimensional filament loops are randomly oriented. The plastic mesh base is 60 to 95 volume percent air. In one improvement, the plastic mesh base has a density of about 0.01 g / cm 3 ~0.200 g / cm 3 . In some improvements, the plurality of three-dimensional filament loops include a plurality of fused connections 464 where two loops are attached to each other.

[0181] In one variant form, the three-dimensional filament ring and, if present, the optional skin layer are composed of a thermoplastic polymer. In one improved form, the three-dimensional filament ring is an extruded thermoplastic polymer. 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 one improved form, the thermoplastic polymer includes linear low-density polyethylene. In some improved forms, the three-dimensional filament ring has a fineness of 200 decitex to 10,000 decitex. In one improved form, the three-dimensional filament ring has a fineness of 200 decitex to 5,000 decitex. In yet another improved form, the three-dimensional filament ring has a fineness of 200 decitex to 3,000 decitex.

[0182] Seat bottom cushions, seat back cushions, headrests, head supports, bolsters, and vehicle seat cushion components (e.g., 430) that can be regions and / or portions are described. The vehicle seat cushion component (e.g., 430) is a plastic mesh base (e.g., 432), which can be an extruded thermoplastic resin mesh, filament, extruded foamed thermoplastic resin, or a three-dimensional filament ring of a polymer, and a plurality of fusion connection parts where two rings are attached to each other. Independently, it contains 60 volume percent to 95 volume percent of air, about 0.01 g / cm 3 ~0.200 g / cm 3 and has a plastic mesh base. The plastic mesh base (e.g., 432) includes a plurality of three-dimensional filament rings. At least a subset of the rings within the plurality of three-dimensional filament rings may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The three-dimensional filament ring contains 60 volume percent to 95 volume percent of air, about 0.01 g / cm 3 ~0.200 g / cm 3It is composed of a thermoplastic polymer that can have a density, each of which is independently formed into the shape of a vehicle seat bolster and can be a polyolefin, a polystyrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The plastic mesh-like base (e.g., 432) has a first edge, a second edge, a first surface that can be an epidermal layer, and a second surface that can be an epidermal layer. The vehicle seat cushion component (e.g., 430) is a first foam bolster (e.g., 450), which can be a foamed polymer, foamed polyurethane, isocyanate, polyol, and / or a suitable foaming agent, and has a holding clip with an end embedded in the foam and a holding clip end attached to the plastic mesh-like base, a hook-shaped body, an annular body connecting strip, a hook-shaped body layer, an annular body layer, an adhesive, a hog ring, a single-sided or double-sided holding clip, joining, welding, sewing, fastening, adhesion, heat caulking, and / or by or without other means of holding, a first foam bolster attached to the plastic mesh-like base (e.g., 432) at the first edge, and a second foam bolster (e.g., 452), which can be a foamed polymer, foamed polyurethane, isocyanate, polyol, and / or a suitable foaming agent, and is attached to the plastic mesh-like base (e.g., 432) at the second edge.

[0183] In some embodiments, the vehicle seat cushion component (e.g., 430) is included in the vehicle seat back or the vehicle seat bottom.

[0184] In some embodiments, the plurality of three-dimensional filament annular bodies include a plurality of fusion connection portions where two annular bodies are attached to each other, which may or may not be parallel or aligned with each other and / or may or may not be randomly oriented.

[0185] In some embodiments, the first foam bolster (e.g., 450) and the second foam bolster (e.g., 452) are each independently composed of a foam polymer, which may be a polyurethane foam.

[0186] In some embodiments, the first foam bolster (e.g., 450) and the second foam bolster (e.g., 452) are each independently composed of a foam polymer, an isocyanate, a polyol, and / or a polyurethane foam that may be a suitable blowing agent.

[0187] In some embodiments, the first foam bolster (e.g., 450) and the second foam bolster (e.g., 452) are each at least partially disposed on the first surface.

[0188] In some embodiments, the first foam bolster (e.g., 450) is attached to the first edge, and the second foam bolster (e.g., 452) is attached to the second edge.

[0189] In some embodiments, the first foam bolster (e.g., 450) is attached to the plastic mesh base (e.g., 432) by a first retaining clip, and the first foam bolster (e.g., 450) is attached to the plastic mesh base (e.g., 432) by a second retaining clip. The first retaining clip and the second retaining clip each have an end embedded in the foam of the respective first foam bolster or second foam bolster (e.g., 452) and a retaining clip end attached to the plastic mesh base (e.g., 432).

[0190] In some embodiments, at least a subset of the annuli within the plurality of three-dimensional filamentous annuli are not parallel or aligned with each other.

[0191] In some embodiments, the annuli within the plurality of three-dimensional filamentous annuli are randomly oriented.

[0192] In some embodiments, the plastic reticulate body base (e.g., 432) is 60 to 95 volume percent air.

[0193] In some embodiments, the plastic reticulate body base (e.g., 432) is about 0.01 g / cm 3 ~0.200 g / cm 3 in density.

[0194] In some embodiments, the thermoplastic polymer is an extruded thermoplastic polymer.

[0195] In some embodiments, the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, styrenic thermoplastic elastomers, polyester thermoplastic elastomers, polyurethane thermoplastic elastomers, and polyamide thermoplastic elastomers.

[0196] In some embodiments, the thermoplastic polymer comprises linear low density polyethylene.

[0197] In some embodiments, the plurality of three-dimensional filament loops have a fineness of 200 to 10,000 decitex.

[0198] Vehicle seat cushion parts (e.g., 430) that can be a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, a region, and / or a portion are disclosed. The vehicle seat cushion parts are a plastic reticulate body base (e.g., 432), which can be an extruded thermoplastic resin reticulate body, a filament body, an extruded foamed thermoplastic resin, or a three-dimensional filament loop of a polymer, and a plurality of fusion joints where two loops are attached to each other, and independently, 60 to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3including the density, having a plastic mesh base, the plastic mesh base (e.g., 432) includes a plurality of three-dimensional filament rings, and at least a subset of the rings within the plurality of three-dimensional filament rings may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The three-dimensional filament ring may be composed of a thermoplastic polymer having a density of about 0.01 g / cm 3 ~0.200 g / cm 3 and is formed into the form of a vehicle seat bolster independently. Each may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene.

[0199] In some embodiments, the vehicle seat cushion component (e.g., 430) is included in the vehicle seat back or the vehicle seat bottom.

[0200] In some embodiments, the plurality of three-dimensional filament rings includes a plurality of fusion connections where two rings are attached to each other.

[0201] In some embodiments, the rings within the plurality of three-dimensional filament rings are randomly oriented.

[0202] In some embodiments, the plastic mesh base (e.g., 432) is 60 volume percent to 95 volume percent air.

[0203] In some embodiments, the thermoplastic polymer includes a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

[0204] The above techniques are optionally combined with one or more elements of the methods described above / below. For example, these portions can be used with one or more of the methods 400, 1600, 1650, 1680, 2700, 3800.

[0205] FIG. 25 shows a seat assembly 520 according to one embodiment. The seat assembly 520 is shown as a vehicle seat that can be employed as a seat assembly in a land vehicle, an aircraft, a ship, etc. The seat assembly 520 can be employed in any row within a vehicle as an individual chair or a bench chair. Alternatively, the seat assembly 520 can also be employed as an office chair or any other chair. The seat assembly 520 omits a conventional foam to improve support and comfort. The seat assembly 520 can also optionally employ a recyclable material manufactured to be further recyclable at the end of the use of the seat assembly 520.

[0206] The seat assembly 520 includes a seat bottom 522 sized to receive a seated occupant and support the occupant's pelvis and thighs. The seat assembly 520 also includes a seat back 524 extending upright from the seat bottom 522 and sized to support the occupant's back. A headrest (or head support) 526 can also be supported above and over the seat back 524 to support the occupant's head. The seat bottom 522 is adapted to be supported by a support surface below. In the illustrated embodiment, the seat assembly 520 includes a pair of rails 528 for attaching the seat bottom 522 to the vehicle floor so that the seat bottom 522 can be adjusted back and forth relative to the vehicle floor. The seat back 524 can also be adjustable to recline relative to the seat bottom 522. In the illustrated embodiment, the headrest 526 is shown integrated with and uniform with the seat back 524, but in some embodiments, it can be separate and thus adjustable in the height direction, the tilt direction, and the front-back direction. As is known in the art, other adjustments can be provided.

[0207] The seat bottom 522 can comprise a frame (not shown) for providing a rigid structural support to the seat bottom 522. Similarly, the seat back 524 can also comprise a frame (not shown) connected to the seat bottom frame that extends upright from the seat bottom 522 and provides a rigid structural support to the seat back 524. In some embodiments, a single (integral) frame can be used for both the seat bottom 522 and the seat back 524, optionally, to provide a rigid structural support. These / This frame is optionally formed from a punched steel alloy, a fiber-reinforced polymer, or any suitable structural material.

[0208] Conventional seat assemblies comprise multiple foam layers that collectively provide cushioning on a frame. The foam layers have different densities and provide a flexible support to the occupant while dispersing the forces from the occupant to the frame. The foam layers also provide comfort to the occupant. Additionally, some non-foam materials have been found to improve support, comfort, performance, and compactness while also serving to facilitate the future recycling of the materials at the end of the use of the seat assembly. Accordingly, the present disclosure relates to the use of non-foam materials to provide cushioning on a frame.

[0209] Referring further to FIG. 25, the seat bottom 522 and the seat back 524 of the seat assembly 520 can optionally further include one or more seat bottom cushions 530 and one or more seat back cushions 532. One or more seat bottom cushions 530, one or more seat back cushions 532, or both can include a non-foam material. In some embodiments, the non-foam material of one or more seat bottom cushions 530, one or more seat back cushions 532, or both is optionally one or more filamentous mesh materials.

[0210] Referring now to FIG. 26, one of the seat bottom cushions 530 is shown partially removed from the seat assembly 520. The seat bottom cushion 530, which may be the same as one or more seat back cushions 532, although not essential, may be formed from a plurality of filaments 534 or annular bodies of extruded foamed thermoplastic resin. In some embodiments, the seat bottom cushion 530 is also optionally formed with or joined to at least one layer (or film) 536 formed or joined using a plurality of filaments 534. The layer 536 may be joined to the plurality of filaments 534 by the curing of the thermoplastic resin or by other joining means such as compression molding, adhesives, mechanical fasteners (e.g., clamps, hog rings, axially fastened members with angled and ribbed deflectors (also known as Christmas tree fastening members), hook-and-loop fasteners, etc.), sewing, etc. In some embodiments, the layer 536 is also optionally an extruded thermoplastic resin material, a nonwoven material, or both. In one exemplary embodiment, the nonwoven material of the layer 536 optionally includes jute, a biodegradable plant fiber.

[0211] Referring to FIG. 27, the layer 536 optionally provides a surface for attaching other seat components 538, 540 by means such as adhesives, mechanical fasteners, etc. (e.g., clamps, hog rings, Christmas tree fastening members, hook-and-loop fasteners, etc.). In the illustrated embodiment, the other seat components 538, 540 are attached to the layer 536 by a clamp ring 542, also known as a hog ring 542. These other seat components 538, 540 are optionally one or more of a trim cover, an actuator such as an airbag assembly, and a heat transfer layer such as a heating mat.

[0212] In the illustrated embodiment, the hog ring 542 attached to the compression molded jute 536 and the foamed thermoplastic resin mesh 534 provides a mounting that withstands tension. For example, this embodiment withstands a tensile load of at least 50 Newtons and up to 151 Newtons, with a deformation of at least 26 millimeters and up to 44 millimeters.

[0213] Accordingly, a seat assembly is disclosed herein that includes a seat bottom, a seat back, and a seat trim assembly, where the seat trim assembly is optionally located on the seat bottom, the seat back, or both. The seat trim assembly disclosed herein optionally further includes at least one fabric sized to be displaced across the surface of a cushion, and at least one retainer coupled to the at least one fabric along the periphery of the fabric to receive trim components. In some embodiments, the seat trim assembly optionally further includes a cushion that includes a filament mesh material. Similarly, in some embodiments, the seat trim assembly optionally further includes a trim cover sized to at least partially surround the cushion and the at least one fabric such that the trim cover is coupled to the at least one retainer. The at least one retainer can be directly or indirectly coupled to the cushion, the trim components, or the trim cover.

[0214] The trim components of the seat trim assembly can be an actuator such as an airbag assembly, a heat transfer layer such as a heating mat, or any combination thereof. The retainers of the seat trim assembly can be one or more of at least one crimp ring, hog ring, Christmas tree fastening member, surface fastener, etc., or any combination thereof. The at least one fabric of the seat trim assembly can be any non-woven material, fabric, textile, or any combination thereof. In some embodiments, the non-woven material of the at least one fabric further includes jute.

[0215] In some embodiments of the present disclosure, a seat assembly is disclosed that includes a seat bottom, a seat back, and a product formed by a method including the following steps, where the product can be on the seat bottom, the seat back, or both. These steps optionally include the steps of coupling at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a cushion, and coupling a trim part to at least one retainer. In some embodiments, the method further includes compression molding at least one fabric to the contour of the cushion before stacking at least one fabric on the cushion. In other embodiments, at least one fabric may be coupled to the contour of the cushion via mechanical fasteners such as adhesives, clamps, hog rings, Christmas tree fastening members, surface fasteners, etc. before stacking at least one fabric on the cushion. At least one retainer may be directly or indirectly coupled to at least one retainer. In an exemplary embodiment where at least one retainer is a clamp ring, another step of the method is to clamp at least one clamp ring to the fabric. In some embodiments, stacking at least one fabric on a cushion optionally further includes stacking at least one fabric on a filament mesh material cushion.

[0216] In some embodiments, the product formed by the above-described method further includes coupling a trim cover sized to at least partially surround a cushion and at least one fabric to at least one retainer. In some exemplary embodiments, the trim component of the product formed by the method can be an actuator such as an airbag assembly, a heat transfer layer such as a heating mat, or any combination thereof. The retainer of the product formed by the method can be at least one clamp ring, hog ring, Christmas tree fastening member, surface fastener, etc., or any combination thereof. At least one fabric of the product formed by the method can be any non-woven material, fabric, textile, or any combination thereof. In some exemplary embodiments, the non-woven material of the at least one fabric further includes jute.

[0217] According to another aspect of the present disclosure, a trim assembly manufactured from the following method is disclosed. The method includes coupling at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a cushion, and coupling a trim component such as an actuator, a heat transfer layer, or any combination thereof to at least one retainer. In some embodiments, the method optionally further includes at least partially surrounding the cushion and at least one fabric by coupling a trim cover to at least one retainer. The at least one retainer that can be directly or indirectly coupled to at least one fabric, cushion, or trim component is optionally one or more of at least one clamp ring, hog ring, Christmas tree fastening member, surface fastener, etc., or any combination thereof. At least one fabric of the trim assembly manufactured by the above-described method can be any non-woven material, fabric, textile, or any combination thereof. In some embodiments, the non-woven material of the at least one fabric further includes jute.

[0218] An assembly (e.g., seat assembly 520) that can be a vehicle seat, an office chair, a personal chair, etc. is described. The assembly (e.g., 520) includes at least one fabric that can be a non-woven material, a biodegradable plant fiber, jute, and / or an extruded thermoplastic resin material. The at least one fabric is dimensioned to be displaced across the surface of a cushion (e.g., 530 and / or 532), which can be a filamentous mesh material, an annular body of extruded foam thermoplastic resin, an extruded thermoplastic resin mesh body, a filamentous body, an extruded foam thermoplastic resin or a three-dimensional filament annular body of a polymer, and a plurality of fused connection parts where two annular bodies are adhered to each other, and independently contains 60 volume percent to 95 volume percent of air, about 0.01 g / cm 3 ~0.200 g / cm 3 of density. At least one retainer (e.g., 542) is coupled to the at least one fabric along the periphery of the fabric by a crimp ring, a hog ring, an axially fastened member with a deflected and angled rib, a surface fastener, sewing, an adhesive, welding, caulking, a connecting strip, a retaining clip, a clamp, a return fastening part, lamination and / or compression molding, and can receive a trim part (e.g., 538 and / or 540) that can be one or more panels of a trim cover, a non-woven material, a biodegradable plant fiber, jute, an extruded thermoplastic resin material, a fabric, leather, synthetic leather, vinyl, and / or other materials, an actuator (e.g., 538 and / 540) such as an airbag assembly, a heat transfer layer (e.g., 538 and / 540) such as a heating mat, or any combination thereof.

[0219] In some embodiments, the assembly includes a cushion (e.g., 530 and / or 532).

[0220] In some embodiments, the cushion (e.g., 530 and / or 532) can be an extruded thermoplastic resin mesh body, a filamentous body, an extruded foam thermoplastic resin or a three-dimensional filament annular body of a polymer, and a plurality of fused connection parts where two annular bodies are adhered to each other, and independently contains 60 volume percent to 95 volume percent of air, about 0.01 g / cm 3~0.200 g / cm 3 including a density of, and at least a subset of the annular bodies within the plurality of three-dimensional filament annular bodies may or may not be parallel to each other or aligned, may be randomly oriented, and may further include a filamentous mesh material having a fineness of 200 decitex to 10,000 decitex.

[0221] In some embodiments, the assembly may include a trim cover that is dimensioned to at least partially surround a cushion (e.g., 530 and / or 532) and at least one fabric, and may be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials, and the trim cover is coupled to at least one retainer.

[0222] In some embodiments, at least one retainer (e.g., 542) includes at least one clamping ring (e.g., 542).

[0223] In some embodiments, at least one retainer (e.g., 542) is not directly coupled to the cushion (e.g., 530 and / or 532).

[0224] In some embodiments, at least one fabric further includes a non-woven material.

[0225] In some embodiments, the non-woven material further includes jute.

[0226] A seat assembly is described that can be a vehicle seat, an office chair, a personal chair, etc. The seat assembly includes a seat bottom, a seat back, and a seat trim assembly on the seat bottom or the seat back. The seat trim assembly may be one or more panels of a trim cover, non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials.

[0227] Described are products that can be seat bottom cushions, seat back cushions, headrests, head supports, bolsters, regions and / or parts. The products include at least one retainer (e.g., 542) that can be a clamp ring, hog ring, axially fastened member with angled and ribbed deflection, surface fastener, sewing, adhesive, welding, caulking, connecting strip, retaining clip, clamp, snap fastener, lamination and / or compression molding, which is not directly coupled to the cushion, and is coupled to the periphery of at least one fabric that can be a non-woven material, biodegradable plant fiber, jute and / or extruded thermoplastic resin material, and can be a filamentous mesh material, an annular body of extruded foam thermoplastic resin, an extruded thermoplastic resin mesh body, a filament, an annular body of extruded foam thermoplastic resin or polymer 3D filaments, a plurality of fused connections where two annular bodies are adhered to each other. Independently, at least one fabric is stacked on a cushion (e.g., 530 and / or 532) having a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3 and is formed by a method including coupling at least one retainer (e.g., 542) to a trim part that can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl and / or other materials, an actuator that can be an airbag assembly, a heat transfer layer that can be a heating mat or any combination thereof (by or without retainer, clamp ring, hog ring, axially fastened member with angled and ribbed deflection, surface fastener, sewing, adhesive, welding, caulking, connecting strip, retaining clip, clamp, snap fastener, lamination and / or compression molding).

[0228] In some embodiments, the method further includes compression molding at least one fabric to the contour of a cushion (e.g., 530 and / or 532) before stacking the at least one fabric on the cushion (e.g., 530 and / or 532).

[0229] In some embodiments, the method further includes coupling a trim cover dimensioned to at least partially surround a cushion (e.g., 530 and / or 532) and at least one fabric to at least one retainer (e.g., 542), which may be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials (by means of a retainer, a crimp ring not directly coupled to the cushion, a hog ring, a shaft fastening member with a rib angled and deflected, a surface fastener, sewing, an adhesive, a weld, caulking, a connecting strip, a retaining clip, a clamp, a snap fastener, lamination and / or compression molding or without and / or thereby).

[0230] In some embodiments, stacking at least one fabric on a cushion (e.g., 530 and / or 532) further includes stacking at least one fabric on a cushion of a filamentous mesh material.

[0231] In some embodiments, the method further includes not directly coupling at least one retainer (e.g., 542) to the cushion (e.g., 530 and / or 532).

[0232] In some embodiments, the method further includes clamping at least one crimp ring to at least one retainer (e.g., 542) of the fabric.

[0233] A seat assembly is described that can be a vehicle seat, an office chair, a personal chair, etc. The seat assembly includes a seat bottom, a seat back, and any product according to the techniques described above or below, which is on the seat bottom or the seat back.

[0234] FIG. 27B shows a method 2700 according to some embodiments. The method 2700 is for coupling a retainer (e.g., 542), such as a crimp ring, hog ring, angled and ribbed shaft fastening member, surface fastener, sewing, adhesive, weld, caulking, connecting strip, retaining clip, clamp, return fastening, lamination and / or compression molding, etc., that is not directly coupled to the cushion, to a fabric that can be a non-woven material, biodegradable plant fiber, jute and / or an extruded thermoplastic resin material. In various examples, the method 2700 can have more or fewer steps than those described below, and the various steps can be performed in a different order, continuously or simultaneously.

[0235] The method 2700 includes (with or without by a retainer, crimp ring, hog ring, angled and ribbed shaft fastening member, surface fastener, sewing, adhesive, weld, caulking, connecting strip, retaining clip, clamp, return fastening, lamination and / or compression molding) coupling at least one retainer (e.g., 542) to a periphery of at least one fabric that can be a non-woven material, biodegradable plant fiber, jute and / or an extruded thermoplastic resin material (2702). The method 2700 can be a filamentous mesh material, an extruded foam thermoplastic resin annulus, an extruded thermoplastic resin mesh, a filament, an extruded foam thermoplastic resin or a three-dimensional filament annulus of a polymer, a plurality of fused connections where two annuli are attached to each other, and independently, an air cushion (e.g., 530 and / or 532) containing from 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3 including stacking at least one fabric on the cushion (2704). The method 2700 includes coupling at least one retainer (e.g., 542) to one or more panels of a trim part that can be a non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl and / or other materials, an actuator that can be an airbag assembly, a heat transfer layer that can be a heating mat, or any combination thereof (2706).

[0236] In some embodiments, method 2700 includes at least partially surrounding a cushion (e.g., 530 and / or 532) and at least one fabric by coupling at least one trim cover, which can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials, to at least one retainer (e.g., 542).

[0237] In some embodiments, the at least one fabric further includes a non-woven material.

[0238] A trim assembly is described that can be one or more panels of non-woven material, biodegradable plant fiber, jute, extruded thermoplastic resin material, fabric, leather, synthetic leather, vinyl, and / or other materials. The trim assembly is manufactured from any of the methods described above or subsequent techniques.

[0239] The techniques described above are optionally combined with one or more elements of the methods described above / hereinafter. For example, these parts can be used with one or more of methods 400, 1600, 1650, 1680, 3800.

[0240] Referring to FIG. 28, a seat assembly 620, such as a vehicle seat assembly 620, is shown. In other examples, the seat assembly 620 can be shaped and sized as a front row driver's or passenger's seat, second row, third row, or other rear row seat, and can include a bench style seat, bucket seat, or other seat style as shown. Further, the seat assembly 620 can be a non-stowable seat or a stowable seat that is foldable and stowable within a cavity in the vehicle floor. Additionally, the seat assembly 620 can be configured for use in applications other than vehicles.

[0241] The seat assembly 620 has a frame 622 or other support structure. The seat assembly has seat components, which include at least a seat bottom 624 and a seat back 626. The seat bottom 624 can be dimensioned to receive a seated occupant and support the occupant's pelvis and thighs. The seat back 626 can be dimensioned to extend upright from the seat bottom 624 and support the occupant's back. The seat assembly 620 can additionally have a headrest 627, which is shown only for an adjacent seat assembly.

[0242] The seat assembly 620 has a cushion 640 that defines a seat bottom cushion region 628 for the seat bottom 624 and a seat back cushion region 630 for the seat back 626. The frame 622 can comprise a wire suspension mat or other structure that supports the cushion 640. The cushion 640 will be described in further detail below according to various examples and embodiments.

[0243] The frame 622 provides a rigid structural support for the seat components, such as the cushion 640, the seat bottom 624, and the seat back 626, and can be provided as a plurality of frame members movable relative to each other to provide adjustments for the seat assembly. The frame can be formed from a stamped steel alloy, a fiber-reinforced polymer, or any suitable structural material. The frame 622 can further include a substrate, such as a panel, for supporting the cushion 640.

[0244] One or more trim covers 632 are used to cover the cushion 640 and provide a seat surface 654 for the seat assembly 620. The vehicle seat assembly 620 is shown without a trim cover, and an adjacent seat assembly shows the trim cover 632. In one example, the trim cover 632 covers both the cushion regions 628, 630. In other examples, a plurality of trim covers are provided to cover the seat bottom cushion region and the seat back cushion region. The trim cover 632 can be formed from one or more panels of fabric, leather, synthetic leather, vinyl, or other materials.

[0245] In the illustrated example, the seat cushion 640 includes at least one non-foam part or member 642. In one example, as illustrated, the seat cushion 640 is formed only from the member 642 such that the non-foam part 642 provides all of the cushioning for the seat component between the frame 622 and the trim cover 632. In other examples, the seat cushion 640 may be formed from the member 642 and one or more foam parts, such as a part formed from molded polyurethane foam, and / or one or more non-foam parts, such as a secondary member 648 described below. The seat cushion 640 may have non-foam and foam parts positioned to provide different regions of the cushion 640 for the seat component, for example, a central region and side bolster regions. Alternatively or in addition, the seat cushion 640 may have a thin layer of foam or other material positioned between the cushion 640 and the trim cover 632 to provide additional cushioning in one or more regions of the seat component. Additionally, the seat assembly 620 may have a heating pad or heating mat positioned between the cushion 640 and the trim cover 632. By removing some or all of the traditional foam from the seat cushion 640, the seat assembly 620 may be provided with improved support and comfort, as well as reduced weight.

[0246] In one non-limiting example, the non-foam parts or members 642 of the seat cushion 640 are formed by a threaded mesh material, also known as an intertwined three-dimensional filament structure. The threaded mesh material is made of a polymer mesh having a plurality of integrated polymer threads. The threaded mesh material may be made of, for example, a linear low density polyethylene (LLPDE) material, although other polymers and materials effective to provide the desired properties and functionality are contemplated. The threaded mesh material may be formed using extruded filaments of linear low density polyethylene (LLDPE) that are randomly intertwined, bent, looped, or otherwise positioned 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. 29.

[0247] Referring to FIGS. 28, 33, and 37, member 642 according to various embodiments is shown. Member 642 can be used as a cushion for a seat assembly such as vehicle seat assembly 620 or for other non-vehicle or non-seat applications. Member 642 of cushion 640 may be formed from a filamentous mesh material, for example, as a single one-piece part from a single extrusion as described below, or may be formed from only the filamentous mesh material. Further, the filamentous mesh material may include a polymer mesh having a plurality of integrated polymer filaments as described above.

[0248] Member 642 defines a first end region 650 and a second end region 652, and the first end region 650 and the second end region 652 are bounded by the outer periphery of the member. In various examples, the first end region 650 is shaped to define or provide a seat back cushion region 630, and the second end region 652 is shaped to define or provide a seat bottom cushion region 628.

[0249] Member 642 also defines a first surface 654 for supporting an occupant on the cushion and a second surface 656 on the opposite side of the first surface and spaced from the first surface. The first surface 654 extends across the first end region 650 and the second end region 652, and the second surface 656 extends across the first end region 650 and the second end region 652. The first surface 654 is positioned on seat assembly 620 to support an occupant of the seat assembly. Side surface 658 may extend around the perimeter of member 642 and between the first surface 654 and the second surface 656.

[0250] The member 642 is shown in a first position in FIGS. 32 and 36 and in a second use position in FIGS. 28, 33, and 37. In FIGS. 28, 33, and 37, the member 642 has a first end region 650 positioned at a non-zero angle θ with respect to a second end region 652. In one non-limiting example, as shown in FIGS. 33 and 37, the non-zero angle θ can be in the range of 90 degrees to 120 degrees, and further can be in the range of 90 degrees to 150 degrees. In other examples, other non-zero angle ranges can also be contemplated. In the first position, the member 642 is provided in the as-extruded shape, and further, the first end region 650 and the second end region 652 can be oriented at an angle of zero or substantially zero with respect to each other. As used herein, "substantially" means within a range of 5 degrees, 10 degrees, or 15 degrees of the described orientation. The member 642 can be bent, folded, curved, or otherwise oriented from the first position to the second position, as further described below.

[0251] According to one example, the member 642 is formed, curved, bent, or folded from the first position as shown in FIG. 32 to the second position as shown in FIG. 33. As shown, a transition region 660 can be provided between the first end region and the second end region.

[0252] According to another example, the member 642 may be formed or provided with one or more grooves 662 that provide a relief for shaping, curving, bending or folding the member 642 from a first position to a second position. In the illustrated example, the one or more grooves 662 are oriented to extend transversely across the member 642. The grooves 662 may extend across the entire member 642 or only a portion thereof. In the illustrated example, the grooves 662 are provided as open grooves that intersect the first surface 654 and not the second surface 656 of the member 642. In other examples, the grooves may additionally or alternatively intersect the second surface 656 and / or the side surface 658. The grooves 662 may be positioned between the first end region 650 and the second end region 652 of the member 642, e.g., in the transition region 660, to provide a relief for bending or shaping the member 642 from the first position to the second position.

[0253] In one example, each groove 662 has a first surface 664 and a second surface 672, and the grooves 662 can be shaped to have a V-shape, U-shape, or other cross-sectional shape when the member is in the first position. A V-shaped groove 662 is shown according to one non-limiting example. The first surface 664 and the second surface 672 mate, contact, or otherwise move toward one another when the member 642 is in the second position as shown in FIG.

[0254] The first surface 664 and the second surface 672 may be interconnected to hold the member 642 in the second position as shown in FIG. 37. In one example, one or more groove fasteners 668 are provided to connect the first surface 664 to the second surface 672 and hold the member 642 in the second position. The groove fasteners 668 may be provided by hog rings, hook and loop fasteners, barbed fasteners, clips, or the like. In another example, the first surface 664 and the second surface 672 may additionally or alternatively be joined to one another via a lamination or welding process, for example, via an adhesive or by fusing threads on one surface to threads on the other surface.

[0255] In other examples, other grooves may alternatively or additionally be formed or provided in member 642, may extend in various directions, and may further be positioned to intersect the second surface 656, side surface 658, or multiple surfaces.

[0256] In various examples, cushion 640 also includes one or more secondary members 648 supported by member 642, as shown in FIGS. 28 and 34. These secondary members 648 can be provided from separate extrusions of a filamentous mesh material, other non-foam materials, foams such as molded polyurethane foam, or combinations thereof. Secondary member 648 may extend outwardly from the first surface 654 and / or the second surface 656 of member 642, and may also extend outwardly from the first end region 650 and / or the second end region 652. In one example, secondary member 648 can form an element of cushion 640, such as a side bolster or lumbar pad or bolster.

[0257] Secondary member 648 can be connected to member 642 to form cushion 640. In one example, one or more secondary fasteners 670 are provided to connect secondary member 648 to member 642. Secondary fastener 670 may be provided by hog rings, surface fasteners, return fasteners, clips, etc. In another example, secondary member 648 may alternatively or additionally be joined to member 642 via, for example, a lamination or welding process such as through an adhesive or by melting filaments on one surface to filaments on the other surface.

[0258] Although secondary member 648 is shown only with respect to FIGS. 28 and 34, it is also contemplated that the secondary member may be attached or otherwise supported by member 642 of FIG. 37.

[0259] FIG. 30 shows a manufacturing process 700 for forming a filamentous mesh material member, such as member 642, for cushion 640 according to one embodiment.

[0260] Hopper 710 holds a stock of material to be extruded, for example, as solid granules or pellets of the material. The material may be provided by a plastic such as linear low-density polyethylene (LLDPE). The material is supplied from hopper 710 to extruder 720.

[0261] Extruder 720 melts the material and conveys it to die plate 730. In one non-limiting example, extruder 720 includes a barrel that houses a rotatable screw and a heating element. As the screw rotates, the material moves through the barrel and the friction generated by the rotation of the screw helps heat the material. The material exits extruder 720 in a molten state under pressure.

[0262] Die plate 730 extrudes the material into filaments 740. Die plate 730 may be provided as described below according to the direction of extrusion with respect to the final member 642 to be manufactured therefrom. More specifically, die plate 730 has a plurality of small circular through-holes or openings through which the molten material passes. A single filament 740 is extruded from each die plate hole. Filaments 740 fall downward from the die plate to funnel 750 under the pressure and gravity of the system as described below. Funnel 750 may have a cross-sectional shape that is the same as or different from the shape collectively defined by the openings of the die plate.

[0263] The funnel 750 serves to connect or bundle the filaments 740 into a more compact arrangement where the filaments 740 bend or become looped and each filament 740 contacts and joins at least one other filament 740. The funnel 750 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. The funnel 750 is narrower at the funnel outlet than at the funnel inlet. The individual, separated filaments 740 enter the funnel inlet, and as the filaments 740 accumulate and slide down the funnel 750 toward the funnel outlet, they bend / loop and move to contact each other, and the connected filament structure 760 exits the funnel outlet and immediately enters the water tank. In various examples, the filament structure can slide down the angled surface of the funnel 750, thereby creating a material skin of the structure 760 formed from the equivalent of two or three rows of filaments adjacent to the periphery of the structure 760.

[0264] The liquid tank 770 holds water 772 or another fluid and receives the connected filament structure 760 from the funnel 750. The liquid 772 within the tank 770 serves to temporarily support the connected filament structure 760, preventing the filament structure from collapsing or condensing into a configuration with a low aperture or porosity and maintaining the desired porosity and density. From this, the liquid 772 provides some resistance that causes the filaments 740 to bend additionally and become looped, further constructing the connected filament structure 760. Second, the liquid 772 cools the filaments 740 from the outside, solidifying the filaments 740 and preventing the filaments 740 from joining at additional locations.

[0265] The tank 770 includes various rollers and conveyors, such as a tractor conveyor 780, that serve to move the connected filament structure 760 through the liquid 772 and out of the liquid 772. The speed of the rollers and conveyors can be controlled to move the connected filament structure 760 away from the funnel 750 at a speed that depends on the speed at which the connected filament structure 760 exits the funnel 750.

[0266] Other rollers, such as roller 782, serve to keep the connecting filament structure 760 immersed in the liquid 772 and guide the connecting filament structure 760 through the liquid 772 towards the conveyor belt 790 and the shaker table 792 located outside the tank 770. The shaker table 792 vibrates the connecting filament structure 760 while it is on the conveyor belt 790 to remove the liquid 772. Pressurized air may be blown towards the connecting filament structure 760 in addition or as an alternative and / or the connecting filament structure 760 may be squeezed to remove the liquid 772.

[0267] Next, the connecting filament structure 760 can be cut to the desired dimensions and shape. In one example, with respect to the die 730 or the funnel 750 as shown in FIG. 31, by cutting across the connecting filament structure 760, the first surface 654 or the second surface 656 of the member 642 is formed. In another example, with respect to the die 730 or the funnel 750 as shown in FIG. 35, by cutting across the connecting filament structure, the side surface 658 of the member 642 is formed.

[0268] Optionally, the member 642 may be further machined or cut to form grooves, passages or shapes within the member 642.

[0269] FIG. 31 shows a top view of a tool 800, such as a die 730 and / or a funnel 750, for use with the manufacturing process 700 according to one embodiment of FIG. 30. FIG. 32 shows a schematic side view of the filamentous mesh material member 642 as provided by the tool 800 in a first configuration or position. Note that the resulting member 642 can be seen in FIG. 28 as a perspective view in a second position according to one non-limiting example.

[0270] In one example, FIG. 31 shows a top view of tool 800 as die 730, with the filament flowing down into die 730. The openings are arranged in a pattern as shown within a bounded perimeter 802 to form a first end region 650 and a second end region 652 of the member, for example, a seat back cushion region and a seat base cushion region. Funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the pattern formed by the die opening.

[0271] Regarding the resulting connected filament structure 760, the structure is cut such that the cut forms the first surface 654 or the second surface 656 as described above, and member 642 retains an outer peripheral shape as shown by the die and / or funnel pattern / perimeter 802. Further, when the connected filament structure 760 is cut, for example, across the page with reference to FIG. 31, the side surface 658 of the resulting member 642 is formed by the extruded connected filament structure 760. Thus, the thickness of member 642 or the length of side surface 658 is determined by where the connected filament structure 760 is cut.

[0272] FIG. 35 shows a top view of tool 820 such as die 730 and / or funnel 750 for use with manufacturing process 700 according to another embodiment of FIG. 30. FIG. 36 shows a schematic side view of a filamentous mesh-like material member 642 as provided by tool 820 in a first configuration or position. Note that the resulting member 642 can be seen in FIG. 28 as a perspective view in a second position according to one non-limiting example.

[0273] In one example, FIG. 35 shows a top view of tool 820 as die 820, and the filaments flow down into die plate 730. The openings are arranged in a pattern as shown within bounded perimeter 822 so as to form the first end region 650 and the second end region 652 of the member, e.g., the seat back cushion region and the seat base cushion region, and to form a groove through region 824. Funnel 750 has a cross-sectional shape similar to the cross-sectional shape of the pattern formed by the die opening and groove 62. Funnel 750 has a cross-sectional shape similar to the cross-sectional shape of perimeter 822 formed by the die opening. In other examples, only funnel 750 forms region 824 for providing a groove within the filament structure, and die 730 does not have this structure.

[0274] Regarding resulting connected filament structure 760, the structure is cut such that the cut forms side surface 658 as described above, and member 642 retains a cross-sectional shape as shown by the die pattern and / or funnel shape 822. Further, when connected filament structure 760 is cut, for example, across the page with reference to FIG. 35, the first surface 654 and the second surface 656 of resulting member 642 are formed by the extruded connected filament structure, e.g., by edges 826, 828 of die 730. Thus, the width of member 642 or the distance between opposing side surfaces 658 on the left and right sides of member 642 is determined by where connected filament structure 760 is cut.

[0275] In yet another example, the die 730 and the funnel 750 may be shaped in a longitudinal direction, for example, to extrude from the top to the bottom, and may include a region 824 for forming a groove portion that extends longitudinally along the member, as opposed to the transverse direction as described above. In this example, the resulting first surface 654 and second surface 656 of the member 642 are formed by the extruded connecting filament structure 760. Thus, the length of the member 642 or the distance between the upper portion of the member 642 adjacent to the headrest and the opposing bottom of the member 642 is determined by where the connecting filament structure is cut and the sides of the upper and bottom of the member 642 are formed.

[0276] A method is provided that can be used to form the member 642, assemble the cushion 640, and assemble the seat assembly 220. In various examples, the method can have more or fewer steps than those described below, and the various steps can be performed in a different order, continuously, or simultaneously.

[0277] The member 642 is formed using a filamentous mesh material, for example, via the process as described above with respect to FIG. 30. The filamentous mesh material can be formed by extruding the material through the die 730 to form the first end region 650 and the second end region 652 of the member, flowing the extruded material through the die and through the funnel 750, and moving the extruded material through one or more rollers 680, 682 after the funnel.

[0278] Furthermore, one or more groove portions 662 can be formed during at least one of extruding the material, flowing the extruded material, and moving the extruded material. Alternatively, the groove portions 662 may be formed in the member 642 after cutting the connecting filament structure to form the member.

[0279] The extruded material or the connecting filament structure 760 is cut to form at least one outer surface of the member. The outer surface may extend across the first end region 650 and the second end region 652 and may be the first surface 654, the second surface 656 or the side surface 658. When the member 642 is cut from the connecting filament structure 760, the member 642 is in the first position as shown in FIGS. 32 and 36. The member 642 may be further machined or otherwise processed to form other features such as grooves or passages for use in connecting the trim assembly or for positioning or receiving various components or systems of the seat assembly.

[0280] As shown in FIGS. 33 and 37, the first end region 650 of the filamentous mesh material member 642 is oriented at a non-zero angle with respect to the second end region 652 of the member to move the member from the first position to the second position. In one example, the filamentous mesh material member 642 is bent or curved from the first position to the second position to orient the member. The groove 662, if provided, may provide a relief or location for the bend or curve.

[0281] The first end region 650 is held at a non-zero angle with respect to the second end region 652 with the member 642 in the second position. In various examples, one or more groove fasteners 668 are inserted into the opposing sides or surfaces 664, 672 of the groove, the opposing sides 664, 672 of the groove are joined to each other, or a combination of these two is used to hold the first end region 650 in the second position with respect to the second end region 652.

[0282] One or more secondary members 648 are formed. The secondary member 648 can be formed separately from the member 642 from a filamentous mesh material similar to that shown in FIG. 29 described above with respect to the process of FIG. 30. Alternatively, the secondary member 648 may be formed as another non-foamed member or a foamed member. The secondary member 648 is attached to the member 642. The secondary member 648 can be attached to the member 642 when the member 642 is in the first position and / or the second position. The secondary member 648 can be further attached to the first surface 654, the second surface 656, and / or the side surface 658 of the member 642. In various examples, one or more secondary fasteners 670 are inserted into the secondary member 648 and the member 642 to hold the secondary member 648 to the member 642, the secondary member 648 is joined to the member 642, or a combination of the two is used.

[0283] The member 642 is attached to the frame 622 of the seat assembly to provide its cushion 640. A trim cover 632 can be positioned over the member 642 and the cushion 640. The trim cover 632 can be connected to the cushion 640 and / or the frame 622.

[0284] Various embodiments provide a single extrusion of the member 642 to form a general area for the cushion 640 that includes the seat back 626 and the seat bottom 624. By further including the groove portion 662 and / or the secondary member 648, the desired shape of the cushion 640 is provided while maintaining the ease of a single extrusion.

[0285] The terms seat assembly, seat or chair may be used herein generally to refer to an assembly incorporating the teachings of one or more of the embodiments disclosed herein, which may include any embodiment or any combination of features of the embodiments disclosed herein. Similarly, the terms seat assembly, seat or chair may refer to the same or similar assemblies. The seat bottom, back, base, headrest, head support or bolster may be used herein generally to refer to any part, region or portion of a seat assembly, vehicle seat or chair. A layer, sheet, substrate, part, region or portion formed from any disclosed material or combination of materials and providing comfort and / or structure to the seat bottom, back, base, headrest, head support or bolster may refer to any planar, non-planar, shaped or contoured part or region of the seat bottom, back, base, headrest, head support or bolster. Joining, connecting, welding, sewing, fastening, holding, adhering, attaching, bonding or caulking may refer to any manufacturing method or process for connecting parts, either with or without fasteners, holders, adhesives, welds, hog rings, connecting straps, retaining clips, surface fasteners, clamps, angled-flexure ribbed shaft fastening members, reversible fasteners, laminating, compression molding or additional trim parts. Filaments, filaments, bends or loops may be used herein to generally refer to linear polymer units after being extruded through one or more orifices of other deformed forms thereof, which are similarly used herein to refer to dies, plates, die plates, tools, tool plates, extrusion dies or breaker plates or equivalent parts (however, they may be fused, joined or looped together to form a mesh-like structure). Similarly, the terms connecting filament structure, filament structure, entangled filament structure, yield strands, body, mesh, end member, non-foamed part, non-woven mesh, non-foamed material, support, part, core, member, extruded material, cushioning material, cushion or cushion part may refer to the same or similar parts. The terms funnel and cover may also be used to refer to the same or similar parts.The description herein can also use various terms to refer to holes such as pores, orifices, nozzles, openings, etc. In yet another example, tanks, water tanks, cooling chambers, liquid tanks, and reservoirs 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 when describing different preferred embodiments. These terms can be interchangeable because various components of features from various embodiments can be combined in ways not explicitly described herein. This does not detract from the fact that, unless otherwise specified, a particular term can provide unique details not included in other interchangeable terms (for example, water tanks and liquid tanks refer to similar interchangeable components, but in at least one preferred embodiment, a tank is filled with or arranged to be filled with water rather than any liquid when a water tank is used).

[0286] Seat bottom cushion, seat back cushion, headrest, headrest, bolster, area, and cushion (e.g., 640) that may be a part are described. The cushion (e.g., 640) comprises a member (e.g., 642) that may be a foam, non-foam, and / or a combination thereof. The member (e.g., 642) may be a plurality of integrated polymer filaments, an entangled three-dimensional filament structure, linear low-density polyethylene, a polymer network with extruded filaments, and includes a filamentous network material that is randomly entangled, bent, annular, or otherwise positioned and oriented and / or directly joined to each other to provide a porous network structure. The member (e.g., 642) defines a first end region (e.g., 650) that may be shaped to define a seat back cushion and a second end region (e.g., 652) that may be shaped to define a seat base cushion. The first end region (e.g., 650) and the second end region (e.g., 652) are bounded by the outer periphery of the member (e.g., 642). The first end region (e.g., 650) is positioned (bent, folded, curved, and / or oriented) at a non-zero angle (such as 90 degrees to 120 degrees or 90 degrees to 150 degrees) with respect to the second end region (e.g., 652).

[0287] In some embodiments, the member (e.g., 642) is formed from only the filamentous network material.

[0288] In some embodiments, the filamentous network material includes a polymer network having a plurality of integrated polymer filaments.

[0289] In some embodiments, the first end region (e.g., 650) is shaped to define a seat back cushion and the second end region (e.g., 652) is shaped to define a seat base cushion.

[0290] In some embodiments, the member (e.g., 642) further comprises a first surface for supporting a passenger on the cushion (e.g., 640) and a second surface opposite the first surface, the first surface extending across a first end region (e.g., 650) and a second end region (e.g., 652), and the second surface extending across the first end region and the second end region.

[0291] In some embodiments, the member (e.g., 642) defines one or more grooves, which may be V-shaped, U-shaped and / or may provide reliefs for shaping, curving, bending, or folding, each groove intersecting one of the first surface and the second surface, which may extend transversely and / or intersect the side surface.

[0292] In some embodiments, the groove extends transversely across the member (e.g., 642) and is positioned between the first end region (e.g., 650) and the second end region (e.g., 652).

[0293] In some embodiments, the groove comprises a first surface and a second surface, and the first surface and the second surface fit together.

[0294] In some embodiments, the cushion (e.g., 640) further comprises one or more groove fasteners (e.g., 668) that connect the first surface to the second surface to hold the first end region (e.g., 650) at a non-zero angle relative to the second end region (e.g., 652).

[0295] In some embodiments, one or more secondary members (e.g., 648) such as a bolster or lumbar supported by the member (e.g., 642).

[0296] In some embodiments, the secondary member (e.g., 648) comprises a filamentous mesh material.

[0297] In some embodiments, the secondary member (e.g., 648) extends outwardly from at least one of the first end region (e.g., 650) and the second end region (e.g., 652) of the member (e.g., 642).

[0298] In some embodiments, the cushion (e.g., 640) further comprises one or more secondary member (e.g., 648) fasteners that can be hog rings, surface fasteners, loop fasteners, clips, adhesives, laminations, and / or welds that connect the secondary member (e.g., 648) to the member (e.g., 642).

[0299] In some embodiments, the secondary member (e.g., 648) is shaped to form a side bolster or a lumbar pad and is positioned on the member (e.g., 642).

[0300] A seat assembly is described that can be a vehicle seat, an office chair, and / or a personal chair. The seat assembly includes a frame, a wire suspension mat, a substrate, and / or a panel that can be a punched and formed steel alloy, a fiber-reinforced polymer, and / or any suitable structural material, and a cushion (e.g., 640) by any of the techniques described above or hereinafter. The cushion (e.g., 640) is supported by the frame.

[0301] A tool is described. The tool includes a die (e.g., 730) (or funnel) that defines a series of openings arranged to extrude a material for a filamentous mesh material member for a cushion (e.g., 640) by any of the techniques described above or hereinafter. The series of openings is arranged to define an outer perimeter of a member (e.g., 642) that includes a seat back region and a seat base region.

[0302] In some embodiments, the series of openings is further arranged such that the outer perimeter defines one or more grooves for the member (e.g., 642).

[0303] In some embodiments, the series of openings is arranged such that one or more grooves are positioned between the seat back region and the seat base region.

[0304] Figure 38 shows a method 3800 according to some embodiments. The method 3800 may be a polymer network having a plurality of integrated polymer filaments, an entangled three-dimensional filament structure, linear low density polyethylene, and extruded filaments, which may be randomly entangled, bent, looped or otherwise positioned and oriented and / or directly joined to each other to provide a porous network structure, for positioning (e.g., bent, folded, curved and / or oriented) filamentous network material members. In various examples, the method 3800 may have more or fewer steps than those described below, and the various steps may be performed in a different order, continuously or simultaneously.

[0305] The method 3800 may be a polymer network having a plurality of integrated polymer filaments, an entangled three-dimensional filament structure, linear low density polyethylene, and extruded filaments, which may be randomly entangled, bent, looped or otherwise positioned and oriented and / or directly joined to each other to provide a porous network structure, and positioning a first end region (e.g., 650) of a filamentous network material member (e.g., 642) that can be shaped to define a seat back cushion at a non-zero angle (e.g., 90 degrees to 120 degrees and / or 90 degrees to 150 degrees) with respect to a second end region (e.g., 652) of the member (e.g., 642) (3802) (e.g., bending, folding, curving and / or orienting), and holding the first end region (e.g., 650) at a non-zero angle with respect to the second end region (e.g., 652) by or without hog rings, hook-and-loop fasteners, return fasteners, clips, adhesives, laminations and / or welds (3804).

[0306] In some embodiments, the method 3800 includes forming a filamentous network material member (e.g., 642) by extruding material through a die.

[0307] In some embodiments, the filamentary mesh material member (e.g., 642) is extruded to form a first end region (e.g., 650) and a second end region (e.g., 652).

[0308] In some embodiments, forming the filamentary mesh material member (e.g., 642) further includes flowing the extruded material from the die through a funnel.

[0309] In some embodiments, method 3800 includes moving the extruded material after the funnel via one or more rollers.

[0310] In some embodiments, method 3800 includes forming one or more grooves during at least one of extruding the material, flowing the extruded material, and moving the extruded material, which may be by extrusion, die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automated machining operations.

[0311] In some embodiments, method 3800 includes cutting one or more grooves in the member (e.g., 642), which may be by die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automated machining operations.

[0312] In some embodiments, method 3800 includes inserting one or more fasteners such as hog rings, hook-and-loop fasteners, reversible fasteners, clips, adhesives, laminations, and / or welds into opposite sides of the groove and / or joining the opposite sides of the groove to hold the first end region (e.g., 650) against the second end region (e.g., 652).

[0313] In some embodiments, method 3800 includes cutting an extruded material to form an outer surface of a member (e.g., 642), which can be by die cutting, robotic laser cutting, water jet cutting, laser cutting, and / or other flexible automated machining operations, and the outer surface extends across a first end region (e.g., 650) and a second end region (e.g., 652).

[0314] In some embodiments, method 3800 includes bending a filamentous mesh material member (e.g., 642) from a first position to a second position to orient the member (e.g., 642).

[0315] In some embodiments, method 3800 includes attaching one or more secondary members (e.g., 648) to a member (e.g., 642), which can use hog rings, hook-and-loop fasteners, reversible fasteners, clips, adhesives, laminations, and / or welds.

[0316] In some embodiments, method 3800 includes forming a secondary member (e.g., 648) from the filamentous mesh material by extrusion or the like.

[0317] In some embodiments, attaching a secondary member (e.g., 648) to a member (e.g., 642) further includes inserting one or more fasteners, which can be hog rings, hook-and-loop fasteners, reversible fasteners, clips, adhesives, laminations, and / or welds, into the secondary member (e.g., 648) and the member (e.g., 642) and / or joining the secondary member (e.g., 648) to the member (e.g., 642).

[0318] In some embodiments, method 3800 further includes attaching a member (e.g., 642) to a frame, wire suspension mat, substrate, and / or panel, such as a punched steel alloy, fiber-reinforced polymer, or any suitable structural material of a seat assembly, to provide a cushion (e.g., 640) therefor.

[0319] The above-described techniques are optionally combined with one or more elements of the above-described methods. For example, these parts can be used together with other methods 400, 1600, 1650, 1680, 2700.

[0320] Item 1. A seat support attached to a seat frame and supporting a passenger on the seat frame, comprising a plurality of flat layers stacked on top of each other, each of the plurality of stacked layers having a different density, and either combined with or not combined with any of the subsequent items.

[0321] Item 2. The seat support according to any of the preceding or subsequent items, wherein the plurality of stacked layers are different such that the density continuously increases from the passenger support surface to the base layer.

[0322] Item 3. The seat support according to any of the preceding or subsequent items, wherein the plurality of stacked layers are different such that the hardness continuously increases from the passenger support surface to the base layer.

[0323] Item 4. The seat support according to any of the preceding or subsequent items, wherein the plurality of stacked layers are connected together.

[0324] Item 5. The seat support according to any of the preceding or subsequent items, wherein each consecutive pair of the plurality of stacked layers are joined together.

[0325] Item 6. The seat support according to any of the preceding or subsequent items, wherein each consecutive pair of the plurality of stacked layers are welded, sewn, fastened or adhered together.

[0326] Item 7. The seat support according to any of the preceding or subsequent items, further comprising rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate or polypropylene.

[0327] Item 8. The plurality of stacked layers further includes a base layer adapted to be attached to the seat frame, the base layer being formed of a material having a higher density than the other layers of the plurality of stacked layers, the seat support according to any of the preceding or following items.

[0328] Item 9. The base layer is formed of an elastomeric material, the seat support according to any of the preceding or following items.

[0329] Item 10. The base layer is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or foamed polyvinyl chloride, the seat support according to any of the preceding or following items.

[0330] Item 11. The base layer has a thickness of 2 millimeters or less, the seat support according to any of the preceding or following items.

[0331] Item 12. A seat assembly comprising a substrate adapted to be attached to the seat frame and the seat support according to any of the preceding or following items stacked on the substrate.

[0332] Item 13. The substrate is formed of an elastomeric material, the seat assembly according to any of the preceding or following items.

[0333] Item 14. The substrate is formed of ethylene propylene diene monomer rubber, thermoplastic polyurethane or foamed polyvinyl chloride, the seat assembly according to any of the preceding or following items.

[0334] Item 15. Further comprising a seat frame, the substrate being attached to the seat frame, the seat assembly according to any of the preceding or following items.

[0335] Item 16. A seat support that is attached to a seat frame and supports a passenger on the seat frame, comprising a plurality of flat layers, the plurality of flat layers being stacked on top of each other, and the plurality of stacked layers having different densities that increase continuously from the passenger support surface to the base layer, either in combination with or not in combination with any of the preceding or subsequent items.

[0336] Item 17. A method of manufacturing a seat assembly, comprising unwinding a first sheet of a first material, cutting a first seat support layer from the first sheet, installing the first seat support layer on a substrate, unwinding a second sheet of a second material having a lower density than the first material, cutting a second seat support layer from the second sheet, and installing the second seat support layer on the first seat support layer, either in combination with or not in combination with any of the preceding or subsequent items.

[0337] Item 18. The method according to any of the preceding or subsequent items, further comprising unwinding a third sheet of a third material having a lower density than the second material, cutting a third seat support layer from the third sheet, and installing the third seat support layer on the second seat support layer.

[0338] Item 19. The method according to any of the preceding or subsequent items, further comprising joining the second seat support layer to the first seat support layer.

[0339] Item 20. A seat assembly manufactured by the method according to any of the preceding or subsequent items.

[0340] Item 21. A seat support that is attached to a seat frame and supports a passenger on the seat frame, comprising a plurality of layers of an extruded thermoplastic resin mesh, the plurality of layers being stacked on top of each other, either in combination with or not in combination with any of the preceding or subsequent items.

[0341] Item 22. The seat support according to any one of the preceding or subsequent items, wherein at least one of the plurality of stacked layers has a generally uniform thickness.

[0342] Item 23. The seat support according to any one of the preceding or subsequent items, wherein each of the plurality of stacked layers has a generally uniform thickness.

[0343] Item 24. The seat support according to any one of the preceding or subsequent items, further comprising at least two stacked layers.

[0344] Item 25. The seat support according to any one of the preceding or subsequent items, wherein each of the plurality of stacked layers is pivotally connected to each other.

[0345] Item 26. The seat support according to any one of the preceding or subsequent items, wherein at least one recess is formed in one of the plurality of stacked layers to provide a pivotable connection.

[0346] Item 27. The seat support according to any one of the preceding or subsequent items, wherein each of the plurality of stacked layers is integrally formed.

[0347] Item 28. A seat assembly comprising a seat frame and a seat support according to any one of the preceding or subsequent items attached to the seat frame.

[0348] Item 29. A seat support attached to a seat frame and supporting a passenger on the seat frame, the seat support comprising a plurality of layers stacked on top of each other, at least one of the plurality of stacked layers having a generally uniform thickness, each of the plurality of stacked layers being integrally formed, and each of the plurality of stacked layers being pivotally connected to each other, either in combination with or not in combination with any one of the preceding or subsequent items.

[0349] A method of manufacturing a product, which may or may not be combined with any of the preceding or subsequent items, including forming a plurality of cushion parts from an extruded thermoplastic resin mesh body and stacking the plurality of cushion parts as cushions.

[0350] Item 31. The method according to any one of the preceding or subsequent items, further including forming a plurality of cushion parts.

[0351] Item 32. The method according to any one of the preceding or subsequent items, further including forming a plurality of cushion parts as an integral sheet.

[0352] Item 33. The method according to any one of the preceding or subsequent items, further including folding the cushion parts so as to stack the cushion parts on one another.

[0353] Item 34. The method according to any one of the preceding or subsequent items, further including forming at least one recess in at least one of the plurality of cushion parts for folding the cushion parts.

[0354] Item 35. The method according to any one of the preceding or subsequent items, further including cutting the plurality of cushion parts for forming the plurality of cushion parts.

[0355] Item 36. A seat support manufactured from any one of the preceding or subsequent items.

[0356] Item 37. The method according to any one of the preceding or subsequent items, further including installing the product on a seat frame.

[0357] Item 38. A seat assembly manufactured by the method according to any one of the preceding or subsequent items.

[0358] Item 39. A method of designing a seat cushion, either in combination with or not in combination with any of the preceding or subsequent items, comprising obtaining a design of an integral seat cushion and redesiging the integral seat cushion design into a plurality of stacked cushion part designs.

[0359] Item 40. The method according to any of the preceding or subsequent items, further comprising redesiging the integral seat cushion design into a plurality of stacked cushion part designs, each having a common maximum thickness.

[0360] Item 41. A method of manufacturing a seat cushion, comprising designing a plurality of cushion part designs according to any of the preceding or subsequent items and forming the plurality of cushion parts from an extruded thermoplastic resin mesh.

[0361] Item 42. The method according to any of the preceding or subsequent items, further comprising stacking the plurality of cushion parts as a cushion.

[0362] Item 43. A vehicle seat cushion part, either in combination with or not in combination with any of the preceding or subsequent items, comprising a first plastic mesh bolster including a first plurality of three-dimensional filament rings composed of a first thermoplastic polymer, a second plastic mesh bolster including a second plurality of three-dimensional filament rings composed of a second thermoplastic polymer, and a plastic mesh base including a third plurality of three-dimensional filament rings composed of a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first surface, and a second surface, the first plastic mesh bolster being attached to the plastic mesh base at the first edge, and the second plastic mesh bolster being attached to the plastic mesh base at the first edge.

[0363] Item 44. The vehicle seat cushion part is the vehicle seat cushion part described in any of the preceding or subsequent items, which is included in the vehicle seat back or the vehicle seat bottom.

[0364] Item 45. The first plurality of three-dimensional filament annular bodies, the second plurality of three-dimensional filament annular bodies, and the third plurality of three-dimensional filament annular bodies each independently include a plurality of fusion connection parts where two annular bodies are adhered to each other, and are the vehicle seat cushion parts described in any of the preceding or subsequent items.

[0365] Item 46. The first plurality of three-dimensional filament annular bodies and the second plurality of three-dimensional filament annular bodies each independently are formed into a shape for a vehicle seat bolster, and are the vehicle seat cushion parts described in any of the preceding or subsequent items.

[0366] Item 47. The first plastic mesh bolster and the second plastic mesh bolster are each arranged on the first surface, and are the vehicle seat cushion parts described in any of the preceding or subsequent items.

[0367] Item 48. The vehicle seat cushion part is such that the first plastic mesh bolster is attached to the first edge and the second plastic mesh bolster is attached to the second edge, and is described in any of the preceding or subsequent items.

[0368] Item 49. The first plastic mesh bolster and the second plastic mesh bolster are attached to the plastic mesh base by a surface strip, an adhesive, a retaining clip, and / or a hog ring, and are the vehicle seat cushion parts described in any of the preceding or subsequent items.

[0369] Item 50. At least a subset of the annular bodies within the first plurality of three-dimensional filament annular bodies, at least a subset of the annular bodies within the second plurality of three-dimensional filament annular bodies, and at least a subset of the annular bodies within the third plurality of three-dimensional filament annular bodies are not parallel to each other or not aligned, a vehicle seat cushion component according to any of the preceding or subsequent items.

[0370] Item 51. At least a subset of the annular bodies within the first plurality of three-dimensional filament annular bodies, at least a subset of the annular bodies within the second plurality of three-dimensional filament annular bodies, and at least a subset of the annular bodies within the third plurality of three-dimensional filament annular bodies are randomly oriented, a vehicle seat cushion component according to any of the preceding or subsequent items.

[0371] Item 52. The first skin layer is disposed on the first surface of the plastic mesh base body, a vehicle seat cushion component according to any of the preceding or subsequent items.

[0372] Item 53. The first skin layer is disposed on the second surface of the plastic mesh base body, a vehicle seat cushion component according to any of the preceding or subsequent items.

[0373] Item 54. The first plastic mesh bolster, the first plastic mesh bolster, and the plastic mesh base body each independently contain 60% to 95% by volume of air, a vehicle seat cushion component according to any of the preceding or subsequent items.

[0374] Item 55. The first plastic mesh bolster, the second plastic mesh bolster, and the plastic mesh base body each independently have a density of about 0.01 g / cm 3 ~0.200 g / cm 3 and a vehicle seat cushion component according to any of the preceding or subsequent items.

[0375] Item 56. The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently a vehicle seat cushion part according to any of the preceding or subsequent items, which is an extrusion thermoplastic polymer.

[0376] Item 57. The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently a vehicle seat cushion part according to any of the preceding or subsequent items, which is composed of components selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

[0377] Item 58. The first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently a vehicle seat cushion part according to any of the preceding or subsequent items, which is linear low density polyethylene.

[0378] Item 59. The first plurality of three-dimensional filament ring bodies, the second plurality of three-dimensional filament ring bodies, and the third plurality of three-dimensional filament ring bodies have a fineness of 200 decitex to 10,000 decitex, and are vehicle seat cushion parts according to any of the preceding or subsequent items.

[0379] Item 60. A vehicle seat cushion component comprising a first plastic mesh bolster including a first plurality of three-dimensional filament annular bodies composed of a first thermoplastic polymer, a second plastic mesh bolster including a second plurality of three-dimensional filament annular bodies composed of a second thermoplastic polymer, and a plastic mesh base including a third plurality of three-dimensional filament annular bodies composed of a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first surface and a second surface, the first plastic mesh bolster being attached to the plastic mesh base at the first edge, the second plastic mesh bolster being attached to the plastic mesh base at the first edge, and the first plurality of three-dimensional filament annular bodies, the second plurality of three-dimensional filament annular bodies and the third plurality of three-dimensional filament annular bodies each independently including a plurality of fusion joints where two annular bodies are attached to each other, and the plastic mesh base, whether combined with or not combined with any of the preceding or subsequent items.

[0380] Item 61. The vehicle seat cushion component is the vehicle seat cushion component according to any one of the preceding or subsequent items, included in a vehicle seat back or a vehicle seat bottom.

[0381] Item 62. The plastic mesh base is air at 60% to 95% by volume, and is the vehicle seat cushion component according to any one of the preceding or subsequent items.

[0382] Item 63. The first thermoplastic polymer, the second thermoplastic polymer and the third thermoplastic polymer are each independently composed of components selected from the group consisting of polyolefins, styrenic thermoplastic elastomers, polyester thermoplastic elastomers, polyurethane thermoplastic elastomers and polyamide thermoplastic elastomers, and are the vehicle seat cushion components according to any one of the preceding or subsequent items.

[0383] Item 64. A vehicle seat cushion component comprising a first bolster assembly including a first core cushion portion surrounded by a first outer bolster cover surrounded by a first bolster start trim cover, a second bolster assembly including a second core cushion portion surrounded by a second outer bolster cover, and a trim cover portion having a first edge and a second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge and the second bolster assembly is sewn to the trim cover portion at the second edge, the vehicle seat cushion component being combined or not combined with any of the preceding or subsequent items.

[0384] Item 65. The vehicle seat cushion component is the vehicle seat cushion component according to any of the preceding or subsequent items, included in a vehicle seat back or a vehicle seat bottom.

[0385] Item 66. The first bolster assembly and the second bolster assembly are each independently formed by compression molding, the vehicle seat cushion component according to any of the preceding or subsequent items.

[0386] Item 67. The first outer bolster cover and the second outer bolster cover each independently include a non-woven fabric, the vehicle seat cushion component according to any of the preceding or subsequent items.

[0387] Item 68. The first outer bolster cover and the second outer bolster cover each independently include natural fibers, the vehicle seat cushion component according to any of the preceding or subsequent items.

[0388] Item 69. The vehicle seat cushion component according to any of the preceding or subsequent items, further comprising a central cushion component positioned within an opening defined by the trim cover portion.

[0389] Item 70. The first core cushion part, the second core cushion part, and the central cushion component are each independently a vehicle seat cushion component as described in any of the preceding or subsequent items, which is composed of foamed polyurethane.

[0390] Item 71. The first core cushion part, the second core cushion part, and the central cushion component are each independently a vehicle seat cushion component as described in any of the preceding or subsequent items, which is composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer.

[0391] Item 72. The plurality of three-dimensional filament annular bodies include a plurality of fused connection parts where two annular bodies are adhered to each other, and it is a vehicle seat cushion component as described in any of the preceding or subsequent items.

[0392] Item 73. At least a subset of the annular bodies within the plurality of three-dimensional filament annular bodies are not parallel to each other or not aligned, and it is a vehicle seat cushion component as described in any of the preceding or subsequent items.

[0393] Item 74. The first core cushion part, the second core cushion part, and the central cushion component are each independently a vehicle seat cushion component as described in any of the preceding or subsequent items, and they are 60 volume percent to 95 volume percent air.

[0394] Item 75. The first core cushion part, the second core cushion part, and the central cushion component are each independently a vehicle seat cushion component as described in any of the preceding or subsequent items, and they each have a density of about 0.01 g / cm 3 ~0.200 g / cm 3 and are vehicle seat cushion components as described in any of the preceding or subsequent items.

[0395] Item 76. The thermoplastic polymer is an extruded thermoplastic polymer, and it is a vehicle seat cushion component as described in any of the preceding or subsequent items.

[0396] Item 77. The thermoplastic polymer is composed of components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers, and is a vehicle seat cushion part described in any of the preceding or subsequent items.

[0397] Item 78. The thermoplastic polymer is a biodegradable or recyclable polymer, and is a vehicle seat cushion part described in any of the preceding or subsequent items.

[0398] Item 79. The plurality of three-dimensional filament annular bodies have a fineness of 200 decitex to 10,000 decitex, and are vehicle seat cushion parts described in any of the preceding or subsequent items.

[0399] Item 80. Further includes providing sound absorption and temperature buffering, and is a vehicle seat cushion part described in any of the preceding or subsequent items.

[0400] Item 81. A vehicle seat includes a seat bottom having a seat bottom frame, a seat back attached to the seat bottom and having a seat back frame, and a vehicle seat cushion part attached to the seat bottom frame and / or the seat back frame. The vehicle seat cushion part includes a first bolster assembly including a first core cushion part surrounded by a first outer bolster cover surrounded by a first bolster trim cover, a second bolster assembly including a second core cushion part surrounded by a second outer bolster cover surrounded by a second bolster trim cover, and a trim cover part having a first edge and a second edge, wherein the first bolster assembly is sewn to the trim cover part at the first edge, and the second bolster assembly is sewn to the trim cover part at the second edge. The vehicle seat may or may not be combined with any of the preceding or subsequent items.

[0401] Item 82. The first outer bolster cover and the second outer bolster cover are each independently a vehicle seat as described in any of the preceding or subsequent items, including a non-woven fabric.

[0402] Item 83. The first outer bolster cover and the second outer bolster cover are each independently a vehicle seat as described in any of the preceding or subsequent items, including natural fibers.

[0403] Item 84. The vehicle seat cushion component further includes a central cushion component positioned within an opening defined by a trim cover portion, and is a vehicle seat as described in any of the preceding or subsequent items.

[0404] Item 85. The first core cushion portion, the second core cushion portion, and the central cushion component are each independently a vehicle seat as described in any of the preceding or subsequent items, and are each composed of foamed polyurethane.

[0405] Item 86. The first core cushion portion, the second core cushion portion, and the central cushion component are each independently a vehicle seat as described in any of the preceding or subsequent items, and are each composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer.

[0406] Item 87. The plurality of three-dimensional filament annular bodies include a plurality of fusion connection portions where two annular bodies are attached to each other, and is a vehicle seat as described in any of the preceding or subsequent items.

[0407] Item 88. At least a subset of the annular bodies within the plurality of three-dimensional filament annular bodies are not parallel to each other or not aligned, and is a vehicle seat as described in any of the preceding or subsequent items.

[0408] Item 89. The first core cushion portion and the second core cushion portion are 60 to 95 volume percent air, and is a vehicle seat as described in any of the preceding or subsequent items.

[0409] Item 90. The first core cushion part and the second core cushion part each independently have a density of about 0.01 g / cm 3 to 0.200 g / cm 3 and are vehicle seats according to any one of the preceding or subsequent items.

[0410] Item 91. The thermoplastic polymer is an extruded thermoplastic polymer, and is a vehicle seat according to any one of the preceding or subsequent items.

[0411] Item 92. A plastic mesh base body, the plastic mesh base body includes a plurality of three-dimensional filament annular bodies, the three-dimensional filament annular bodies are composed of a thermoplastic polymer, the plastic mesh base body has a first edge, a second edge, a first surface and a second surface, a plastic mesh base body, a first foam bolster attached to the plastic mesh base body at the first edge, and a second foam bolster attached to the plastic mesh base body at the second edge, and is a vehicle seat cushion part that is combined with or not combined with any one of the preceding or subsequent items.

[0412] Item 93. The vehicle seat cushion part is included in the vehicle seat back or the vehicle seat bottom, and is a vehicle seat cushion part according to any one of the preceding or subsequent items.

[0413] Item 94. The plurality of three-dimensional filament annular bodies include a plurality of fusion connection parts where two annular bodies are adhered to each other, and are vehicle seat cushion parts according to any one of the preceding or subsequent items.

[0414] Item 95. The first foam bolster and the second foam bolster each independently are composed of a foamed polymer, and are vehicle seat cushion parts according to any one of the preceding or subsequent items.

[0415] Item 96. The first foam bolster and the second foam bolster each independently are composed of foamed polyurethane, and are vehicle seat cushion parts according to any one of the preceding or subsequent items.

[0416] Item 97. The first foam bolster and the second foam bolster are each vehicle seat cushion parts as described in any of the preceding or following items, which are at least partially disposed on the first surface.

[0417] Item 98. Vehicle seat cushion parts as described in any of the preceding or following items, wherein the first foam bolster is attached to the first edge and the second foam bolster is attached to the second edge.

[0418] Item 99. The first foam bolster is attached to the plastic mesh base using a first retaining clip, and the first foam bolster is attached to the plastic mesh base using a second retaining clip. The first retaining clip and the second retaining clip each have an end portion embedded in the foam of the respective first foam bolster or second foam bolster and a retaining clip end portion attached to the plastic mesh base. Vehicle seat cushion parts as described in any of the preceding or following items.

[0419] Item 100. At least a subset of the annuli within the plurality of three-dimensional filament annuli are not parallel or aligned with each other. Vehicle seat cushion parts as described in any of the preceding or following items.

[0420] Item 101. The annuli within the plurality of three-dimensional filament annuli are randomly oriented. Vehicle seat cushion parts as described in any of the preceding or following items.

[0421] Item 102. The plastic mesh base is 60 to 95 volume percent air. Vehicle seat cushion parts as described in any of the preceding or following items.

[0422] Item 103. The plastic mesh base is about 0.01 g / cm 3 ~0.200 g / cm 3A vehicle seat cushion part as described in any of the preceding or subsequent items, having the density.

[0423] Item 104. The thermoplastic polymer is an extruded thermoplastic polymer, a vehicle seat cushion part as described in any of the preceding or subsequent items.

[0424] Item 105. The thermoplastic polymer contains components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers, a vehicle seat cushion part as described in any of the preceding or subsequent items.

[0425] Item 106. The thermoplastic polymer contains linear low-density polyethylene, a vehicle seat cushion part as described in any of the preceding or subsequent items.

[0426] Item 107. The plurality of three-dimensional filament ring bodies have a fineness of 200 decitex to 10,000 decitex, a vehicle seat cushion part as described in any of the preceding or subsequent items.

[0427] Item 108. A plastic mesh-like base part that includes a plurality of three-dimensional filament ring bodies, and the three-dimensional filament ring bodies are composed of a thermoplastic polymer, a vehicle seat cushion part that is combined with or not combined with any of the preceding or subsequent items.

[0428] Item 109. The vehicle seat cushion part is included in the vehicle seat back or the vehicle seat bottom, a vehicle seat cushion part as described in any of the preceding or subsequent items.

[0429] Item 110. The plurality of three-dimensional filament ring bodies include a plurality of fusion connection parts where two ring bodies are adhered to each other, a vehicle seat cushion part as described in any of the preceding or subsequent items.

[0430] Item 111. The annular bodies within the plurality of three-dimensional filament annular bodies are randomly oriented vehicle seat cushion parts described in any of the preceding or subsequent items.

[0431] Item 112. The plastic mesh base is 60% to 95% by volume air, and is a vehicle seat cushion part described in any of the preceding or subsequent items.

[0432] Item 113. The thermoplastic polymer contains components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers, and is a vehicle seat cushion part described in any of the preceding or subsequent items.

[0433] Item 114. An assembly, with or without combination with any of the preceding or subsequent items, comprising at least one fabric sized to be displaced across the surface of the cushion, and at least one retainer coupled to the at least one fabric along the periphery of the fabric to receive a trim part, an actuator, a heat transfer layer, or any combination thereof.

[0434] Item 115. An assembly described in any of the preceding or subsequent items, further comprising a cushion.

[0435] Item 116. The assembly described in any of the preceding or subsequent items, wherein the cushion further includes a filamentous mesh material.

[0436] Item 117. An assembly described in any of the preceding or subsequent items, further comprising a trim cover sized to at least partially surround the cushion and the at least one fabric, and the trim cover is coupled to the at least one retainer.

[0437] Item 118. The at least one retainer includes at least one clamping ring, and is an assembly described in any of the preceding or subsequent items.

[0438] Item 119. The assembly according to any of the preceding or subsequent items, wherein at least one retainer is not directly coupled to the cushion.

[0439] Item 120. The assembly according to any of the preceding or subsequent items, wherein at least one fabric further comprises a non-woven material.

[0440] Item 121. The assembly according to any of the preceding or subsequent items, wherein the non-woven material further comprises jute.

[0441] Item 122. A seat assembly comprising a seat bottom, a seat back, and a seat trim assembly according to any of the preceding or subsequent items located on the seat bottom or the seat back.

[0442] Item 123. A product formed by a method, whether combined with or not combined with any of the preceding or subsequent items, comprising coupling at least one retainer to a periphery of at least one fabric, stacking at least one fabric on a cushion, and coupling a trim component, an actuator, a heat transfer layer, or any combination thereof to at least one retainer.

[0443] Item 124. A product formed by a method according to any of the preceding or subsequent items, further comprising compression molding at least one fabric to a contour of the cushion before stacking at least one fabric on the cushion.

[0444] Item 125. A product formed by a method according to any of the preceding or subsequent items, further comprising coupling a trim cover sized to at least partially surround the cushion and at least one fabric to at least one retainer.

[0445] Item 126. A product according to any of the preceding or subsequent items, wherein stacking at least one fabric on a cushion further includes stacking at least one fabric on a filament mesh material cushion.

[0446] Item 127. A product formed by a method according to any of the preceding or subsequent items, further including not directly coupling at least one retainer to a cushion.

[0447] Item 128. A product formed by a method according to any of the preceding or subsequent items, further including clamping at least one clamp ring to a fabric as at least one retainer.

[0448] Item 129. A seat assembly comprising a seat bottom, a seat back, and a product according to any of the preceding or subsequent items located on the seat bottom or the seat back.

[0449] Item 130. A method, whether combined with or not combined with any of the preceding or subsequent items, including coupling at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a cushion, and coupling a trim component, an actuator, a heat transfer layer, or any combination thereof to at least one retainer.

[0450] Item 131. A method according to any of the preceding or subsequent items, further including at least partially surrounding a cushion and at least one fabric by coupling a trim cover to at least one retainer.

[0451] Item 132. A method according to any of the preceding or subsequent items, wherein at least one fabric further includes a non-woven material.

[0452] Item 133. A trim assembly manufactured from a method according to any of the preceding or subsequent items.

[0453] Item 134. A member comprising a filamentous mesh material, the member defining a first end region and a second end region, the first end region and the second end region being bounded by the outer periphery of the member, the member being provided, the first end region being positioned at a non-zero angle relative to the second end region, a cushion, either combined with or not combined with any of the preceding or subsequent items.

[0454] Item 135. The cushion according to any of the preceding or subsequent items, wherein the member is formed from only the filamentous mesh material.

[0455] Item 136. The cushion according to any of the preceding or subsequent items, wherein the filamentous mesh material includes a polymer mesh having a plurality of integrated polymer filaments.

[0456] Item 137. The cushion according to any of the preceding or subsequent items, wherein the first end region is shaped to define a seat back cushion and the second end region is shaped to define a seat base cushion.

[0457] Item 138. The cushion according to any of the preceding or subsequent items, the member further comprising a first surface for supporting a passenger on the cushion and a second surface opposite the first surface, the first surface extending across the first end region and the second end region, the second surface extending across the first end region and the second end region.

[0458] Item 139. The cushion according to any of the preceding or subsequent items, the member defining one or more groove portions, each groove portion intersecting one of the first surface and the second surface.

[0459] Item 140. The cushion according to any of the preceding or subsequent items, wherein the groove portion extends transversely across the member and is positioned between the first end region and the second end region.

[0460] Item 141. The groove part has a first surface and a second surface, and the first surface and the second surface fit with each other, and the cushion according to any one of the preceding or subsequent items.

[0461] Item 142. The cushion according to any one of the preceding or subsequent items, further comprising one or more groove fasteners that connect the first surface to the second surface to hold the first end region at a non-zero angle with respect to the second end region.

[0462] Item 143. The cushion according to any one of the preceding or subsequent items, further comprising one or more secondary members supported by a member.

[0463] Item 144. The cushion according to any one of the preceding or subsequent items, wherein the secondary member includes a filamentous mesh material.

[0464] Item 145. The cushion according to any one of the preceding or subsequent items, wherein the secondary member extends outward from at least one of the first end region and the second end region of the member.

[0465] Item 146. The cushion according to any one of the preceding or subsequent items, further comprising one or more secondary member fasteners that connect the secondary member to the member.

[0466] Item 147. The cushion according to any one of the preceding or subsequent items, wherein the secondary member is shaped to form a side bolster or a lumbar pad and is positioned on the member.

[0467] Item 148. A seat assembly, comprising a frame and a cushion according to any one of the preceding or subsequent items supported by the frame.

[0468] Item 149. A die defining a series of openings arranged to extrude a material for a filamentous mesh material member for a cushion according to any one of the preceding or subsequent items, the series of openings being arranged to define an outer periphery of a member including a seat back region and a seat base region, the tool comprising the die.

[0469] Item 150. The tool according to any one of the preceding or subsequent items, wherein the series of openings is further arranged such that the outer periphery defines one or more groove portions for the member.

[0470] Item 151. The tool according to any one of the preceding or subsequent items, wherein the series of openings is arranged such that one or more groove portions are positioned between the seat back region and the seat base region.

[0471] Item 152. A method, whether combined or not combined with any one of the preceding or subsequent items, including positioning a first end region of a filamentous mesh-like material member at a non-zero angle with respect to a second end region of the member and holding the first end region at a non-zero angle with respect to the second end region.

[0472] Item 153. The method according to any one of the preceding or subsequent items, further including forming a filamentous mesh-like material member by extruding a material through a die.

[0473] Item 154. The method according to any one of the preceding or subsequent items, wherein the filamentous mesh-like material member is extruded to form a first end region and a second end region.

[0474] Item 155. The method according to any one of the preceding or subsequent items, wherein forming the filamentous mesh-like material member further includes flowing the extruded material from the die through a funnel.

[0475] Item 156. The method according to any one of the preceding or subsequent items, further including moving the extruded material after the funnel via one or more rollers.

[0476] Item 157. The method according to any one of the preceding or subsequent items, further including forming one or more groove portions during at least one of extruding the material, flowing the extruded material, and moving the extruded material.

[0477] Item 158. The method according to any one of the preceding or subsequent items, further including cutting one or more grooves in the member.

[0478] Item 159. The method according to any one of the preceding or subsequent items, further including inserting one or more fastening parts into opposite side portions of the groove and / or joining the opposite side portions of the groove to hold the first end region against the second end region.

[0479] Item 160. The method according to any one of the preceding or subsequent items, further including cutting an extruded material to form an outer surface of the member, the outer surface extending across the first end region and the second end region.

[0480] Item 161. The method according to any one of the preceding or subsequent items, further including bending a filamentous mesh material member from a first position to a second position to orient the member.

[0481] Item 162. The method according to any one of the preceding or subsequent items, further including attaching one or more secondary members to the member.

[0482] Item 163. The method according to any one of the preceding or subsequent items, further including forming the secondary member from a filamentous mesh material.

[0483] Item 164. Attaching the secondary member to the member further includes inserting one or more fastening parts into the secondary member and the member and / or joining the secondary member to the member, according to the method described in any one of the preceding or subsequent items.

[0484] Item 165. The method according to any one of the preceding or subsequent items, further including attaching the member to a frame of a seat assembly to provide a cushion therefor.

[0485] Item 166. Any combination of any of the preceding Items 1 to 165.

[0486] Although various embodiments have been described above, it is not intended that these embodiments describe all possible forms according to the present disclosure. In this regard, it is understood that the words used in this specification are words for explanation rather than limitation, and various changes can be made without departing from the spirit and scope of the present disclosure. In addition, the features of various embodiments can be combined to form further embodiments according to the present disclosure.

Claims

1. A seat support, comprising: a) a plurality of flat layers attached to a seat frame and supporting a passenger on the seat frame, the plurality of flat layers being stacked on top of each other, each of the plurality of stacked layers having a different density; b) a plurality of layers or regions of a plastic mesh, the plurality of layers being stacked, attached or positioned at a non-zero angle relative to each other; c) a first bolster assembly including a first core cushion portion surrounded by a first outer bolster cover surrounded by a first bolster trim cover, a second bolster assembly including a second core cushion portion surrounded by a second outer bolster cover, and a trim cover portion having a first edge and a second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge and the second bolster assembly is sewn to the trim cover portion at the second edge; d) a plastic mesh base including a plurality of three-dimensional filament rings, the three-dimensional filament rings being composed of a thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first surface and a second surface, a first foam bolster attached to the plastic mesh base at the first edge, and a second foam bolster and / or attached to the plastic mesh base at the second edge; e) at least one fabric dimensioned to be displaced across a surface of the cushion and at least one retainer coupled to the at least one fabric along a periphery of the fabric to receive a trim component, an actuator, a heat transfer layer, or any combination thereof. A seat support comprising the above.

2. The seat support according to claim 1, further comprising the plurality of flat layers attached to the seat frame and supporting the passenger on the seat frame, the plurality of flat layers being stacked on top of each other, each of the plurality of stacked layers having the different density.

3. The seat support according to claim 1 or 2, wherein the plurality of stacked layers are different such that the density continuously increases from the passenger support surface to the base layer.

4. The seat support according to any one of claims 1 to 3, wherein the plurality of stacked layers are different such that the hardness continuously increases from the passenger support surface to the base layer.

5. The seat support according to any one of claims 1 to 4, wherein the plurality of stacked layers are all connected to each other.

6. The seat support according to any one of claims 1 to 5, wherein each consecutive pair of the plurality of stacked layers are joined together.

7. The seat support according to any one of claims 1 to 6, wherein each consecutive pair of the plurality of stacked layers are welded, stitched, fastened or adhered together.

8. The seat support according to any one of claims 1 to 7, wherein the plurality of stacked layers further comprise rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate or polypropylene.

9. The seat support according to any one of claims 1 to 8, wherein the plurality of stacked layers further comprise a base layer adapted to be attached to the seat frame, and the base layer is formed from a material having a higher density than the other layers of the plurality of stacked layers.

10. The seat support according to claim 9, wherein the base layer is formed from an elastomeric material.

11. The seat support according to claim 9 or 10, wherein the base layer is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane or foamed polyvinyl chloride.

12. The seat support according to claim 11, wherein the base layer has a thickness of 2 millimeters or less.

13. The seat support according to any one of claims 1 to 12, further comprising the plurality of flat layers for supporting the passenger on the seat frame, the plurality of flat layers being stacked on top of each other, and the plurality of stacked layers being different such that the density continuously increases from the passenger support surface to the base layer.

14. The seat support according to any one of claims 1 to 13, further comprising the plurality of layers of the plastic mesh body for supporting the passenger on the seat frame, the plurality of layers being stacked on top of each other, The seat support according to any one of claims 1 to 13, wherein the plastic mesh body further comprises an extruded thermoplastic resin mesh body.

15. The seat support according to any one of claims 1 to 14, wherein at least one of the plurality of stacked layers has a generally uniform thickness.

16. The seat support according to any one of claims 1 to 15, wherein each of the plurality of stacked layers has a generally uniform thickness.

17. The seat support according to any one of claims 1 to 16, wherein the seat support further comprises at least two stacked layers.

18. The seat support according to any one of claims 1 to 17, wherein each of the plurality of stacked layers is pivotally connected to each other.

19. The seat support according to claim 18, wherein at least one recess is formed in one of the plurality of stacked layers to provide the pivotable connection.

20. The seat support according to claim 18 or 19, wherein each of the plurality of stacked layers is integrally formed.

21. Mounted on a seat frame and supporting a passenger on the seat frame, further comprising the plurality of layers, the plurality of layers being stacked on top of each other, wherein at least one of the plurality of stacked layers has a generally uniform thickness, wherein each of the plurality of stacked layers is integrally formed, The seat support according to any one of claims 1 to 20, wherein each of the plurality of stacked layers is pivotally connected to each other.

22. The plurality of layers of the plastic mesh body, a first plastic mesh bolster including a first plurality of three-dimensional filament rings composed of a first thermoplastic polymer, a second plastic mesh bolster including a second plurality of three-dimensional filament rings composed of a second thermoplastic polymer, a plastic mesh base including a third plurality of three-dimensional filament rings composed of a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first surface and a second surface, the first plastic mesh bolster being attached to the plastic mesh base at the first edge, and the second plastic mesh bolster being attached to the plastic mesh base at the first edge, a plastic mesh base, The seat support according to claim 1, further comprising.

23. The vehicle seat cushion part is the seat support according to any one of claims 1 to 22, which is included in the back of the vehicle seat or the bottom of the vehicle seat.

24. The first plurality of three-dimensional filament ring bodies, the second plurality of three-dimensional filament ring bodies, and the third plurality of three-dimensional filament ring bodies each independently include a plurality of fusion connection parts where two ring bodies are attached to each other, and are the seat support according to claim 22 or 23.

25. The first plurality of three-dimensional filament ring bodies and the second plurality of three-dimensional filament ring bodies are each independently formed into a shape for a vehicle seat bolster, and are the seat support according to any one of claims 22 to 24.

26. The first plastic mesh bolster and the second plastic mesh bolster are each disposed on the first surface, and are the seat support according to any one of claims 22 to 25.

29. The first plastic mesh bolster is attached to the first edge, and the second plastic mesh bolster is attached to the second edge, and are the seat support according to any one of claims 22 to 26.

30. The first plastic mesh bolster and the second plastic mesh bolster are attached to the plastic mesh base by a surface strip, an adhesive, a retaining clip, and / or a hog ring, and are the seat support according to any one of claims 22 to 29.

31. At least a subset of the ring bodies in the first plurality of three-dimensional filament ring bodies, at least a subset of the ring bodies in the second plurality of three-dimensional filament ring bodies, and at least a subset of the ring bodies in the third plurality of three-dimensional filament ring bodies are not parallel to each other or not aligned, and are the seat support according to any one of claims 22 to 30.

32. At least a subset of the ring bodies in the first plurality of three-dimensional filament ring bodies, at least a subset of the ring bodies in the second plurality of three-dimensional filament ring bodies, and at least a subset of the ring bodies in the third plurality of three-dimensional filament ring bodies are randomly oriented, and are the seat support according to any one of claims 22 to 31.

33. The seat support according to any one of claims 22 to 32, further comprising a first skin layer disposed on the first surface of the plastic mesh-like body base.

34. The seat support according to any one of claims 22 to 33, further comprising a first skin layer disposed on the second surface of the plastic mesh-like body base.

35. The seat support according to any one of claims 22 to 34, wherein the first plastic mesh-like bolster, the first plastic mesh-like bolster, and the plastic mesh-like body base each independently contain 60 to 95% by volume of air.

36. The first plastic mesh bolster, the first plastic mesh bolster, and the plastic mesh base are each independently about 0.01 g / cm ３ to 0.200 g / cm ３ in density, the seat support according to any one of claims 22 to 35.

37. The seat support according to any one of claims 22 to 36, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extruded thermoplastic polymer.

38. The seat support according to any one of claims 22 to 37, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of components selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

39. The seat support according to any one of claims 22 to 38, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently linear low-density polyethylene.

40. The seat support according to any one of claims 22 to 39, wherein the first plurality of three-dimensional filament annular bodies, the second plurality of three-dimensional filament annular bodies, and the third plurality of three-dimensional filament annular bodies have a fineness of 200 to 10,000 decitex.

41. The plurality of layers of the plastic mesh-like body include a first plastic mesh-like bolster including a first plurality of three-dimensional filament annular bodies composed of a first thermoplastic polymer, a second plastic mesh-like bolster including a second plurality of three-dimensional filament annular bodies composed of a second thermoplastic polymer, A plastic mesh base body including a plurality of third three-dimensional filament annular bodies composed of a third thermoplastic polymer, the plastic mesh base body having a first edge, a second edge, a first surface, and a second surface, the first plastic mesh bolster being attached to the plastic mesh base body at the first edge, the second plastic mesh bolster being attached to the plastic mesh base body at the first edge, the first plurality of three-dimensional filament annular bodies, the second plurality of three-dimensional filament annular bodies, and the third plurality of three-dimensional filament annular bodies each independently including a plurality of fusion joints where two annular bodies are attached to each other, a plastic mesh base body, The seat support according to claim 1, further comprising.

42. The vehicle seat cushion component is the seat support according to any one of claims 1 to 41, which is included in a vehicle seat back or a vehicle seat bottom.

43. The seat support according to any one of claims 22 to 42, wherein the plastic mesh base body is air of 60 volume percent to 95 volume percent.

44. The seat support according to any one of claims 22 to 43, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of components selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

45. The first bolster assembly including the first core cushion portion surrounded by the first outer bolster cover surrounded by the first bolster trim cover, The second bolster assembly including the second core cushion portion surrounded by the second outer bolster cover, The trim cover portion having the first edge and the second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge, and the second bolster assembly is sewn to the trim cover portion at the second edge, the trim cover portion, The seat support according to claim 1, further comprising.

46. The vehicle seat cushion part is the seat support according to any one of claims 1 to 45, which is included in the back part of the vehicle seat or the bottom part of the vehicle seat.

47. The first bolster assembly and the second bolster assembly are each independently the seat support according to any one of claims 45 or 46, which is formed by compression molding.

48. The first outer bolster cover and the second outer bolster cover are each independently the seat support according to any one of claims 45 to 47, which includes a non-woven fabric.

49. The first outer bolster cover and the second outer bolster cover are each independently the seat support according to any one of claims 45 to 48, which includes natural fibers.

50. The seat support according to any one of claims 45 to 49 further includes a central cushion part positioned within the opening defined by the trim cover part.

51. The first core cushion part, the second core cushion part, and the central cushion part are each independently the seat support according to any one of claims 45 to 50, which is composed of foamed polyurethane.

52. The first core cushion part, the second core cushion part, and the central cushion part are each independently the seat support according to any one of claims 45 to 51, which is composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer.

53. The plurality of three-dimensional filament annular bodies include a plurality of fusion connection parts where two annular bodies are adhered to each other, and it is the seat support according to any one of claims 45 to 52.

54. At least a subset of the annular bodies within the plurality of three-dimensional filament annular bodies are not parallel to each other or not aligned, and it is the seat support according to any one of claims 45 to 53.

55. The first core cushion part, the second core cushion part, and the central cushion part are each independently the seat support according to any one of claims 45 to 54, which is 60 volume percent to 95 volume percent air.

56. The first core cushion part, the second core cushion part, and the central cushion component are each independently about 0.01 g / cm ３ to 0.200 g / cm ３ The seat support according to any one of claims 45 to 55, having a density of.

57. The thermoplastic polymer is an extrusion-molded thermoplastic polymer, and it is the seat support according to any one of claims 45 to 56.

58. The seat support according to any one of claims 45 to 57, wherein the thermoplastic polymer is composed of a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

59. The seat support according to any one of claims 45 to 58, wherein the thermoplastic polymer is a biodegradable or recyclable polymer.

60. The seat support according to any one of claims 45 to 59, wherein the plurality of three-dimensional filament annular bodies have a fineness of 200 decitex to 10,000 decitex.

61. The seat support according to any one of claims 45 to 60, further comprising providing sound absorption and temperature buffering.

62. The seat support further comprises a vehicle seat cushion component, wherein the vehicle seat cushion component is the plastic mesh-like body base, the plastic mesh-like body base includes a plurality of three-dimensional filament annular bodies, the three-dimensional filament annular bodies are composed of the thermoplastic polymer, and the plastic mesh-like body base has the first edge, the second edge, the first surface, and the second surface, the plastic mesh-like body base; the first foam bolster attached to the plastic mesh-like body base at the first edge; the second foam bolster attached to the plastic mesh-like body base at the second edge; The seat support according to claim 1, comprising.

63. The seat support according to claim 62, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

64. The seat support according to claim 62 or 63, wherein the plurality of three-dimensional filament annular bodies include a plurality of fusion connection portions where two annular bodies are attached to each other.

65. The seat support according to any one of claims 62 to 64, wherein the first foam bolster and the second foam bolster are each independently composed of a foamed polymer.

66. The seat support according to any one of claims 62 to 65, wherein the first foam bolster and the second foam bolster are each independently composed of foamed polyurethane.

67. The first foam bolster and the second foam bolster are each a seat support according to any one of claims 62 to 66, which are at least partially disposed on the first surface.

68. The seat support according to any one of claims 62 to 67, wherein the first foam bolster is attached to the first edge and the second foam bolster is attached to the second edge.

69. The first foam bolster is attached to the plastic mesh-like base using a first retaining clip, and the first foam bolster is attached to the plastic mesh-like base using a second retaining clip. The first retaining clip and the second retaining clip each have an end portion embedded in the foam of each of the first foam bolster or the second foam bolster and a retaining clip end portion attached to the plastic mesh-like base. The seat support according to any one of claims 62 to 68.

70. The seat support according to any one of claims 62 to 69, wherein at least a subset of the annular bodies in the plurality of three-dimensional filament annular bodies are not parallel to each other or are not aligned.

71. The seat support according to any one of claims 62 to 70, wherein the annular bodies in the plurality of three-dimensional filament annular bodies are randomly oriented.

72. The seat support according to any one of claims 62 to 71, wherein the plastic mesh-like base is 60% to 95% by volume of air.

73. The plastic mesh-like base has a density of about 0.01 g / cm ３ to 0.200 g / cm ３ and is the seat support according to any one of claims 62 to 72.

74. The seat support according to any one of claims 62 to 73, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

75. The seat support according to any one of claims 62 to 74, wherein the thermoplastic polymer contains a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

76. The seat support according to any one of claims 62 to 75, wherein the thermoplastic polymer contains linear low-density polyethylene.

77. The seat support according to any one of claims 62 to 76, wherein the plurality of three-dimensional filament annular bodies have a fineness of 200 decitex to 10,000 decitex.

78. The seat support according to claim 1, further comprising a vehicle seat cushion component, wherein the vehicle seat cushion component comprises the plastic mesh-like base, the plastic mesh-like base includes a plurality of three-dimensional filament rings, and the three-dimensional filament rings are composed of a thermoplastic polymer.

79. The seat support according to claim 78, wherein the vehicle seat cushion component is included in a vehicle seat back or a vehicle seat bottom.

80. The seat support according to claim 78 or 79, wherein the plurality of three-dimensional filament rings include a plurality of fusion connection parts where two rings are attached to each other.

81. The seat support according to any one of claims 78 to 80, wherein the rings in the plurality of three-dimensional filament rings are randomly oriented.

82. The seat support according to any one of claims 78 to 81, wherein the plastic mesh-like base is 60% to 95% by volume of air.

83. The seat support according to any one of claims 78 to 82, wherein the thermoplastic polymer includes a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

84. The seat support according to claim 1, further comprising an assembly, wherein the assembly includes at least one fabric sized to be displaced across the surface of the cushion, and at least one retainer coupled to the at least one fabric along the periphery of the fabric to receive the trim part, the actuator, the heat transfer layer, or any combination thereof.

85. The seat support according to claim 84, further comprising the cushion.

86. The seat support according to claim 85, wherein the cushion further includes a filamentous mesh material.

87. The seat support according to claim 85 or 86, further comprising a trim cover sized to at least partially surround the cushion and the at least one fabric, and the trim cover is coupled to the at least one retainer.

88. The seat support according to claims 84 to 87, wherein the at least one retainer includes at least one clamping ring.

89. The seat support according to claims 84 to 88, wherein the at least one holder is not directly coupled to the cushion.

90. The seat support according to claims 84 to 89, wherein the at least one fabric further comprises a non-woven material.

91. The seat support according to claim 80, wherein the non-woven material further comprises jute.

92. A member including a filamentous mesh material as the plastic mesh body, the member defining a first end region and a second end region, the first end region and the second end region being bounded by an outer periphery of the member, further comprising a member, The seat support according to claim 1, wherein the first end region is positioned at a non-zero angle with respect to the second end region.

93. The seat support according to claim 92, wherein the member is formed only from the filamentous mesh material.

94. The seat support according to claim 93, wherein the filamentous mesh material includes a polymer mesh body having a plurality of integrated polymer filaments.

95. The first end region is shaped to define a seat back cushion, The seat support according to any one of claims 92 to 94, wherein the second end region is shaped to define a seat base cushion.

96. The member further comprises a first surface for supporting a passenger on the cushion and a second surface on the opposite side of the first surface, the first surface extending across the first end region and the second end region, the second surface extending across the first end region and the second end region. The seat support according to any one of claims 92 to 95.

97. The member defines one or more groove portions, each groove portion intersecting one of the first surface and the second surface. The seat support according to claim 96.

98. The seat support according to claim 97, wherein the groove portion extends transversely across the member and is positioned between the first end region and the second end region.

99. The groove portion includes a first surface and a second surface, and the first surface and the second surface fit together. The seat support according to claim 97 or 98.

100. The seat support according to claim 99, further comprising one or more groove fasteners connecting the first surface to the second surface for holding the first end region at the non-zero angle with respect to the second end region.

101. The seat support according to any one of claims 92 to 100, further comprising one or more secondary members supported by the member.

102. The seat support according to claim 101, wherein the secondary member includes a filamentous mesh material.

103. The seat support according to claim 101 or 102, wherein the secondary member extends outwardly from at least one of the first end region and the second end region of the member.

104. The seat support according to any one of claims 101 to 103, further comprising one or more secondary member fastening portions for connecting the secondary member to the member.

105. The seat support according to any one of claims 101 to 104, wherein the secondary member is shaped to form a side bolster or a lumbar pad and is positioned on the member.

106. A base material adapted to be attached to a seat frame, The seat support according to any one of claims 1 to 105, stacked on the base material, and A seat assembly comprising.

107. The seat assembly according to claim 106, wherein the base material is formed from an elastomer material.

108. The seat assembly according to claim 106 or 107, wherein the base material is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane or foamed polyvinyl chloride.

109. The seat assembly according to any one of claims 106 to 108, further comprising a seat frame, and the base material is attached to the seat frame.

110. A seat frame, The seat support according to any one of claims 1 to 105, attached to the seat frame or supported by the seat frame, and A seat assembly comprising.

111. A seat bottom, A seat back, The seat support according to any one of claims 1 to 105, provided on the seat bottom or the seat back, and A seat assembly comprising.

112. A vehicle seat, A seat bottom having a seat bottom frame, A seat back attached to the seat bottom and provided with a seat back frame, The seat support according to any one of claims 1 and 45 to 61, wherein the seat support further comprises a vehicle seat cushion component attached to the seat bottom frame and / or the seat back frame, and the vehicle seat cushion component is The first bolster assembly including the first core cushion portion surrounded by the first outer bolster cover surrounded by the first bolster trim cover; The second bolster assembly including the second core cushion portion surrounded by the second outer bolster cover surrounded by the second bolster trim cover; The trim cover portion having the first edge and the second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge, and the second bolster assembly is sewn to the trim cover portion at the second edge; A vehicle seat comprising the same.

113. The vehicle seat according to claim 112, wherein the first outer bolster cover and the second outer bolster cover each independently include a non-woven fabric.

114. The vehicle seat according to claim 112 or 113, wherein the first outer bolster cover and the second outer bolster cover each independently include natural fibers.

115. The vehicle seat according to any one of claims 112 to 114, further comprising a central cushion component positioned within an opening defined by the trim cover portion.

116. The vehicle seat according to any one of claims 112 to 115, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently composed of foamed polyurethane.

117. The vehicle seat according to any one of claims 112 to 116, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently composed of a plurality of three-dimensional filament annular bodies made of a thermoplastic polymer.

118. The vehicle seat according to any one of claims 112 to 117, wherein the plurality of three-dimensional filament annular bodies include a plurality of fused connection portions where two annular bodies are attached to each other.

119. The vehicle seat according to any one of claims 112 to 118, wherein at least a subset of the annular bodies within the plurality of three-dimensional filament annular bodies are not parallel to each other or not aligned.

120. The vehicle seat according to any one of claims 112 to 119, wherein the first core cushion portion and the second core cushion portion are air at 60 to 95% by volume.

121. The first core cushion portion and the second core cushion portion are each independently about 0.01 g / cm ３ to 0.200 g / cm ３ and have a density, and are the vehicle seat according to any one of claims 112 to 120.

122. The vehicle seat according to any one of claims 112 to 121, wherein the thermoplastic polymer is an extrusion-molded thermoplastic polymer.

123. A die defining a series of openings arranged to extrude a material for the filamentous mesh-like material member for the cushion according to any one of claims 92 to 105, wherein the series of openings are arranged to define the outer periphery of the member including the seat back region and the seat base region, the tool comprising a die.

124. The tool according to claim 123, wherein the series of openings are further arranged such that the outer periphery defines one or more groove portions for the member.

125. The tool according to claim 124, wherein the series of openings are arranged such that the one or more groove portions are positioned between the seat back region and the seat base region.

126. A method of manufacturing a product, a) A first sub-step, i) unwinding a first sheet of a first material, ii) cutting a first seat support layer from the first sheet, iii) installing the first seat support layer on a substrate, iv) unwinding a second sheet of a second material having a density lower than the density of the first material, v) cutting a second seat support layer from the second sheet, vi) installing the second seat support layer on the first seat support layer, comprising the first sub-step, b) A second sub-step, i) forming a plurality of layers or regions of a plastic mesh, ii) stacking or attaching the plurality of layers or regions or positioning the plurality of cushion portions at a non-zero angle relative to each other, comprising the second sub-step, c) A third sub-step, i) sewing a first bolster assembly having a first core cushion portion surrounded by a first outer bolster cover surrounded by a first bolster trim cover to a first edge of a trim cover portion, ii) sewing a second bolster assembly having a second core cushion portion surrounded by a second outer bolster cover to the second edge of the trim cover portion; including a third sub-step; d) a fourth sub-step, i) attaching a first foam bolster to a first edge of a plastic mesh base, the plastic mesh base including a plurality of three-dimensional filament rings, the three-dimensional filament rings being composed of a thermoplastic polymer; ii) attaching a second foam bolster to a second edge of the plastic mesh base; including a fourth sub-step and / or; e) a fifth sub-step, i) coupling at least one retainer to a periphery of at least one fabric; ii) stacking the at least one fabric on a cushion; iii) coupling a trim part, an actuator, a heat transfer layer, or any combination thereof to the at least one retainer; including a fifth sub-step; including a method.

127. The method according to claim 126, further including the first sub-step.

128. unrolling a third sheet of a third material having a density lower than the density of the second material; cutting a third seat support layer from the third sheet; installing the third seat support layer on the second seat support layer; The method according to claim 126 or 127, further including.

129. The method according to any one of claims 126 to 128, further including joining the second seat support layer to the first seat support layer.

130. The method according to claim 126, further including the second sub-step.

131. The method according to claim 126 or 130, further including forming the plurality of cushion portions.

132. The method according to any one of claims 126, 130, and 131, further including forming the plurality of cushion portions as an integral sheet.

133. The method according to claim 132, further including folding the cushion portions so as to stack the cushion portions on top of each other.

134. The method according to claim 133, further including forming at least one recess in at least one of the plurality of cushion portions for folding the cushion portions.

135. The method according to any one of claims 126 and 130 to 134, further comprising cutting the plurality of cushion portions to form the plurality of cushion portions.

136. The method according to claim 126, further comprising the fifth sub-step.

137. The method according to claim 136, further comprising at least partially surrounding the cushion and the at least one fabric by coupling a trim cover to the at least one holder.

138. The method according to claim 136 or 137, wherein the at least one fabric further comprises a non-woven material.

139. positioning a first end region of the filamentous mesh material member of the plurality of cushion portions at a non-zero angle with respect to the second end region of the member; holding the first end region at a non-zero angle with respect to the second end region; The method according to claim 16, further comprising.

140. The method according to claim 139, further comprising forming the filamentous mesh material member by extruding material through a die.

141. The method according to claim 140, wherein the filamentous mesh material member is extruded to form the first end region and the second end region.

142. The method according to claim 140 or 141, wherein forming the filamentous mesh material member further comprises flowing the extruded material from the die through a funnel.

143. The method according to claim 142, further comprising moving the extruded material after the funnel via one or more rollers.

144. The method according to claim 143, further comprising forming one or more grooves during at least one of extruding the material, flowing the extruded material, and moving the extruded material.

145. The method according to any one of claims 140 to 144, further comprising cutting the one or more grooves into the member.

146. The method according to claim 144 or 145, further comprising inserting one or more fastening portions into opposite side portions of the groove and / or joining the opposite side portions of the groove to hold the first end region with respect to the second end region.

147. The method according to any one of claims 140 to 146, further comprising cutting the extruded material to form an outer surface of the member, the outer surface extending across the first end region and the second end region.

148. The method according to any one of claims 139 to 147, further comprising bending the filamentous mesh material member from a first position to a second position to orient the member.

149. The method according to any one of claims 139 to 148, further comprising attaching one or more secondary members to the member.

150. The method according to claim 149, further comprising forming the secondary member from a filamentous mesh material.

151. Attaching the secondary member to the member further comprises inserting one or more fastening portions into the secondary member and the member and / or coupling the secondary member to the member, according to the method of claim 149 or 150.

152. The method according to any one of claims 139 to 151, further comprising attaching the member to a frame of a seat assembly to provide a cushion therefor.

153. A method of designing a seat cushion, comprising: obtaining a design of an integral seat cushion; redesigning the integral seat cushion design into a plurality of stacked, sewn or attached cushion part designs; and a method.

154. The method according to claim 153, further comprising redesigning the integral seat cushion design into the plurality of stacked cushion part designs, each having a common maximum thickness.

155. A method of manufacturing a seat cushion, comprising: designing a plurality of cushion part designs according to claim 153 or 154; forming the plurality of cushion parts from an extruded thermoplastic resin mesh; and a method.

156. The method according to claim 155, further comprising stacking the plurality of cushion parts as a cushion.

157. A seat support manufactured by the method according to any one of claims 139 to 152 or designed by the method according to any one of claims 153 to 56.

158. The method according to any one of claims 139 to 156, further comprising installing the product on a seat frame.

159. A seat assembly manufactured by the method according to claim 158.

160. coupling the at least one retainer to the periphery of the at least one fabric; stacking the at least one fabric on the cushion; coupling the trim component, the actuator, the heat transfer layer, or any combination thereof to the at least one retainer; A seat support manufactured by the method according to claim 157, comprising:

161. A seat support manufactured by the method according to claim 160, further comprising compression molding the at least one fabric to the contour of the cushion before stacking the at least one fabric on the cushion.

162. A seat support manufactured by the method according to claim 160 or 161, further comprising coupling a trim cover sized to at least partially surround the cushion and the at least one fabric to the at least one retainer.

163. A seat support manufactured by the method according to claims 160-162, wherein stacking the at least one fabric on the cushion further comprises stacking the at least one fabric on a filament mesh material cushion.

164. A seat support manufactured by the method according to claims 160-163, further comprising not directly coupling the at least one retainer to the cushion.

165. A seat support manufactured and formed by the method according to claims 160-164, further comprising clamping at least one clamping ring to the fabric as the at least one retainer.

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