METHOD OF MANUFACTURING MESH STRUCTURES AND CROSS-REFERENCE TO RELATED APPLICATIONS

Abstract

The present invention relates to a filament mesh structure, a method for manufacturing and forming the filament mesh structure, and a sheet assembly having the filament mesh structure, which may be cut by a fluid jet and heated with a fluid to facilitate reshaping, and which may include foldable connecting segments to facilitate folding of the filament mesh structure.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of Danish Patent Application No. PA202370186, filed April 21, 2023, which in turn claims priority to U.S. Provisional Application No. 63 / 354288, filed June 22, 2022, U.S. Provisional Application No. 63 / 355785, filed June 27, 2022, and U.S. Provisional Application No. 63 / 356719, filed June 29, 2022, the disclosures of which are incorporated herein by reference in their entireties.

[0002] Various embodiments relate to a cushion-like filament mesh structure, a seat assembly having a filament mesh structure cushion, and one or more methods of manufacturing and forming the filament mesh structure. [Brief explanation of the drawings]

[0003] [Figure 1] FIG. 1 is a perspective view of an example of a seat assembly. [Figure 2] FIG. 1 is a perspective view of an example of a cushion including a filament mesh structure that may comprise a seat assembly. [Figure 3] FIG. 1 is a schematic diagram of an example manufacturing system for producing a filament mesh structure. [Figure 4] FIG. 1 is a perspective view of an example of a cutting system for cutting a filament mesh structure. [Figure 5A] 1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 5B] 1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 5C] 1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 5D] 1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 5E]1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 5F] 1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 5G] 1A-1C are schematic side views of various cuts that can be made with the cutting system. [Figure 6A] 1A-1C are schematic top views of various cuts that can be made with the cutting system. [Figure 6B] 1A-1C are schematic top views of various cuts that can be made with the cutting system. [Figure 7] 1 illustrates an example of a forming system for forming a filament mesh structure with forming tools shown in a retracted position. [Figure 8] 7 shows the forming system of FIG. 7 spraying steam onto the filament mesh structure. [Figure 9] 8 illustrates the forming system of FIG. 7 with a forming tool engaged with the filament mesh structure. [Figure 10] 8 shows the forming system of FIG. 7 with the forming tool in a retracted position after reshaping the filament mesh structure. [Figure 11] FIG. 10 is a perspective view of another example of a shaping system for forming a filament mesh structure with a shaping tool engaged with the filament mesh structure to reshape the filament mesh structure. [Figure 12] FIG. 12 is a cross-sectional view taken along section line 12-12 with the forming tool prior to spraying steam to engage the filament mesh structure. [Figure 13] FIG. 10 is a perspective view of another example of a forming system for forming a filament mesh structure in which steam is sprayed through a nozzle to reshape the filament mesh structure. [Figure 14] FIG. 1 is an enlarged view of a portion of a filament mesh structure showing an example of a filament before being heated and reshaped. [Figure 15] FIG. 15 is an enlarged view of a portion of the filament mesh structure of FIG. 14 showing an example of the filaments after being heated and reshaped. [Figure 16]14 is a flow chart of a method of forming a filament mesh structure associated with the molding system configuration shown in FIGS. 7-13. [Figure 17] 1A and 1B are top and side views of an example portion of a filament mesh structure. [Figure 18] 1A and 1B are top and side views of an example portion of a filament mesh structure. [Figure 19] 19A and 19B are top and side views of the filament mesh structure of FIGS. 17 and 18 after forming. [Figure 20] 19A and 19B are top and side views of the filament mesh structure of FIGS. 17 and 18 after forming. [Figure 21] 21A and 21B are top and side views of the filament mesh structure of FIGS. 19 and 20 after folding. [Figure 22] 21A and 21B are top and side views of the filament mesh structure of FIGS. 19 and 20 after folding. [Figure 23] FIG. 23 is a side view of the filament mesh structure of FIG. 22 with the folded portion of the filament mesh structure locked in the folded position.

[0004] [Detailed explanation] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail as not to unnecessarily obscure aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art how to variously use the embodiments according to the disclosure.

[0006] "One or more" includes functions performed by one element, functions performed by multiple elements, e.g., some functions performed by one element, some functions performed by multiple elements in a distributed manner, or any combination of the above.

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

[0008] The terminology used in describing the various embodiments described herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in describing the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and / or," as used herein, refers to and encompasses any and all possible combinations of one or more of the associated listed items. Furthermore, it will be understood that the terms "have," "had," "include," and / or "included," and the like, when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0009] As used herein, the word "if" will be interpreted to mean "when" or "upon" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [a stated condition or event] is detected" will be interpreted to mean "upon determining" or "in response to determining" or "upon determining" or "in response and determining" or "upon detecting [a stated condition or event]" or "in response to detecting [a stated condition or event]," depending on the context.

[0010] Furthermore, unless expressly indicated otherwise, all numerical values ​​in the specification and claims will be understood as modified by the word "about" in describing the broader scope of the invention. The terms "about," "approximately," or "about" can be used herein to modify values ​​or relative characteristics set forth in the disclosure or claims. In such cases, "about," "approximately," or "about" can mean that the modifying value or relative characteristic is within ±0%, 0.1%, 0.5%, 1%, 2%, 4%, 5%, or 10% of the value or relative characteristic. Practice within the stated numerical limits is generally preferred. Also, unless expressly stated to the contrary, the description of a group or class of materials as suitable or preferred for a given purpose in connection with the present invention means that mixtures of any two or more members of the group or class are equally suitable or preferred.

[0011] Referring to FIG. 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for a land vehicle, such as an automobile, truck, or bus, or a non-land vehicle, such as an aircraft or watercraft. For example, the seat assembly 10 for a land vehicle can be shaped and sized as a front driver or passenger seat, a second-row seat, a third-row seat, or other rear-row seat, and can include a bench-style seat as shown, a bucket seat, or other seat styles. Furthermore, the seat assembly 10 can be a non-stowable seat or a stowable seat that can be folded and stowed into a cavity within the vehicle floor. Furthermore, the seat assembly 10 can be configured for non-vehicle applications, such as furniture.

[0012] 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool.

[0013] The seat bottom 20 is configured to receive a seated occupant and support the pelvis and thighs of the seat occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover .

[0014] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and may be made of any suitable material, such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In one or more configurations, the seat bottom frame 30 includes a panel, a seat pan, a suspension mat, or suspension wires on which the cushion 32 is positioned.

[0015] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a flexible material that supports the seat occupant and distributes load from the seat occupant to the seat bottom frame 30. The cushion 32 and associated manufacturing methods are described in more detail below.

[0016] The trim cover 34 covers at least a portion of the cushion 32. Furthermore, the trim cover 34 provides one or more visible exterior surfaces of the seat back 22. A seat occupant may rest on the trim cover 34 when seated in the seat assembly 10. The trim cover 34 may be made of any suitable material or materials, such as cloth, leather, leatherette, vinyl, or a combination thereof. The trim cover 34 may include multiple trim panels assembled in any suitable manner, such as by fusing or stitching. The trim cover 34 may be attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may include trim attachment features attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 and to help the trim cover 34 conform to the contours of the seat bottom frame 30, the cushion 32, or both.

[0017] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and near the rear side of the seat bottom 20. The seat back 22 extends generally upwardly away from the seat bottom 20. In some configurations, the seat back 22 may be attached to the seat bottom 20 and rotatable relative to the seat bottom 20. In other configurations, the seat back 22 is not attached to the seat bottom 20. For example, the seat back of a vehicle may be attached to the vehicle body structure, such as in some second-row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a trim cover 44, and optionally a headrest 46.

[0018] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and may be made of any suitable material, such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In one or more configurations, the seat back frame 40 includes a panel, pan, suspension mat, or suspension wires on which the cushion 42 is positioned. The seat back frame 40 may also be integrally formed with the seat bottom frame 30.

[0019] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a flexible material that supports a seat occupant and distributes load from the seat occupant to the seat back frame 40. The cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be separate from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods are described in more detail below.

[0020] The trim cover 44 covers at least a portion of the cushion 42. Furthermore, the trim cover 44 provides one or more visible exterior surfaces of the seat back 22. A seat occupant may be positioned on the trim cover 44 when seated in the seat assembly 10. The trim cover 44 may be made of any suitable material or materials, such as cloth, leather, leatherette, vinyl, or a combination thereof. The trim cover 44 may include multiple trim panels assembled by any suitable method, such as fusion or stitching. The trim cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 may include trim attachment features attached to the seat back frame 40, the cushion 42, or both, to prevent removal of the trim cover 44 and to help the trim cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both.

[0021] If provided, the headrest 46 is configured to support the head of a seat occupant. The headrest 46 is located at the top of the seat back 22 or at an end of the seat back 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be formed integrally with the seat back 22.

[0022] 2, an example of a cushion 50 is shown, which for ease of reference is generally referred to by the reference numeral 50. It should be understood that the structure and description of the cushion 50 may be applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0023] The cushion 50 is non-foamed or includes at least one non-foamed component. Non-foamed components are commonly referred to as filament mesh structures, but may also be referred to as stranded wire mesh, mesh cushions, mesh structures, or mesh members. In FIG. 2, the cushion 50 is depicted as a non-foamed component that does not include a foamed component or foam material, such as urethane foam or polyurethane foam. However, it is contemplated that the cushion 50 may include a foamed component or foam material in addition to a non-foamed component to provide additional or localized cushioning for the seat occupant. For example, foam material may be provided between the cushion 50 and a trim cover disposed on the cushion 50 (e.g., trim covers 34, 44), within the cushion 50, or a combination thereof. Reducing the amount of foam material provided with the cushion 50 or removing material from the cushion 50 can reduce weight and improve support and comfort for the seat occupant.

[0024] The cushion 50 is primarily described below in the context of a cushion 50 that is a non-foamed component that does not include any foam material. In this context, the cushion 50 is made of filaments 52 of polymeric material that are randomly bent, curled, or looped and bonded together as described in detail below.

[0025] The filaments 52, also referred to as strands or threads, may be made of any suitable material or materials. In some configurations, the filaments 52 are made of a thermoplastic material or materials, such as a thermoplastic resin that is polyamide-based, polyester-based, polyimide-based, polyolefin-based, polypropylene-based, polystyrene-based, or a combination thereof. As an example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). The filament material may be recyclable, unlike, or more easily recycled than, a foamed material. It is also contemplated that the filaments 52 may include reinforcing fibers, but the reinforcing fibers may not be made of a thermoplastic material.

[0026] The filaments 52 may be monofilaments made of a single material, or may be multi-material filaments 52. By way of example, a multi-material filament 52 may include a core made of a first thermoplastic material and a sheath surrounding the core made of a second thermoplastic material different from the first thermoplastic material. It is also contemplated that the cushion 50 may include a combination of monofilaments and multi-material, non-monofilament filaments.

[0027] The filaments 52 may be randomly bent, looped, curled, or entangled and bonded together where one filament 52 contacts another filament 52, thereby producing a lightweight, air-permeable cushion (e.g., cushion 32 and / or 42) or mesh structure with openings or voids between the filaments 52. An enlarged view of an example of filaments 52 in a mesh structure is shown in FIG. 14. An example of a method for manufacturing a mesh cushion or mesh structure is disclosed in U.S. patent application Ser. No. 17 / 555,875, which is incorporated herein by reference in its entirety. An example manufacturing system 60 for manufacturing a cushion or filament mesh structure is also shown in FIG. 3. In this example, the manufacturing system 60 includes a hopper 70, an extruder 72, a funnel 74, a tank 76, and a material handling subsystem 78.

[0028] 3, a container or hopper 70 holds the feedstock to be extruded, such as solid beads, flakes, granules, pellets, or powder produced from the material. The hopper 70 delivers the feedstock to an extruder 72.

[0029] The extruder 72 melts the feedstock material and extrudes it into filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. Rotation of the screw moves the material through the barrel and helps heat the material due to friction generated as the screw rotates. The material exits the barrel in a molten state under pressure and is transported to a die 80 of the extruder 72.

[0030] The die 80, also known as a die plate or extrusion die, has a plurality of through-holes or filament-forming openings through which molten material passes. A single filament 52 is extruded from each through-hole. The filament 52 falls downward from the die 80 under gravity toward the funnel 74.

[0031] The funnel 74 consolidates or groups the filaments 52 into a more compact arrangement, where the filaments 52 bend, curl, or loop, and each filament 52 contacts and bonds to at least one other filament 52. The funnel 74 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. Individual, separated filaments 52 enter the funnel inlet. As the filaments 52 accumulate, they bend, curl, or loop and move into contact. The filaments 52 slide down the funnel 74 toward the funnel outlet. Bonds are formed between the filaments 52 at the points of contact, but at other locations where one filament 52 does not contact or bond to another filament 52, openings or voids exist between the filaments 52. The tangled, bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter the tank 76. For ease of reference, the bonded filaments 52 are referred to as a filament mesh structure 90.

[0032] The tank 76 holds a liquid, such as water or a mixture of water and another fluid. The liquid within the tank 76 supports the entangled and bonded filaments 52, limiting further compression or consolidation of the filaments 52 and helping to maintain the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance that can further bend, curl, or loop the filaments 52 adjacent the surface of the liquid to further build up the filament mesh structure 90. The liquid also cools the filaments 52 while they are in the liquid. For example, the liquid cools the filaments 52 from the outside, solidifying the filaments 52 and preventing them from bonding together in other locations. At this point, the filaments 52 are relatively rigid and no longer in a plastic state; therefore, they generally maintain their shape and cannot be shaped or deformed without heating.

[0033] The material handling subsystem 78 transports the filament mesh structure 90 through the tank 76. The material handling subsystem 78 includes various rollers and conveyors that help move the filament mesh structure 90 in and out of the liquid. In some configurations, a tractor conveyor 92 is provided within the tank 76 to pull the filament mesh structure 90 away from the funnel 74 and help counter the buoyancy of the filaments 52.

[0034] Other rollers, such as roller 94, keep the filament mesh structure 90 submerged in the liquid and guide the filament mesh structure through the tank 76. For example, roller 94 can guide the filament mesh structure 90 toward a conveyor belt 96 and shaker table 98 located outside the tank 76. The shaker table 98 shakes the filament mesh structure 90 on the conveyor belt 96 to remove the liquid. Alternatively or additionally, the filament mesh structure 90 can be squeezed to remove the liquid, pressurized air can be blown toward the filament mesh structure 90 to remove the liquid, or both.

[0035] The manufacturing system 60 described above is a continuous flow process in which the filament mesh structure 90 is formed as a continuous structure when the filament extrusion is uninterrupted. Further processing of the filament mesh structure 90 occurs after it exits the tank 76, cutting the filament mesh structure 90 into individual components for individual cushions to provide cushions 50 having desired sizes and shapes. For example, the cross-sectional shape of the filament mesh structure 90 can correspond to the shape of the funnel outlet. A manufacturing system 60 having a funnel outlet with a rectangular opening will produce a filament mesh structure 90 with a generally rectangular shape or rectangular cross-section. If a cushion 50 with a different shape or cross-section is desired, additional shaping or shaping steps can be performed. For example, the filament mesh structure 90 may be cut to remove material to shape or contour the outer surface and provide through holes, blind holes, notches, grooves, trenches, or slits, or combinations thereof. Cutting, shaping, and shaping the mesh material can be accomplished using a cutting system 100.

[0036] Referring to FIG. 4, an example of a cutting system 100 is shown. The cutting system 100 is a fluid-based cutting system that provides pressurized fluid for cutting one or more filaments 52 of the filament mesh structure 90. Accordingly, the fluid is the cutting medium. The fluid is described below primarily as a liquid, e.g., liquid water or a fluid that includes liquid water. However, it is contemplated that the fluid may be a gas, or that an abrasive material may be added to the fluid as the cutting medium. In some configurations, the cutting system 100 includes a platform 110, a fluid supply subsystem 112, a cutting head 114, automation 116, and a controller 118. The cutting system 100 may include additional fluid system components, such as filters, accumulators, and vents, which are not shown for simplicity.

[0037] The platform 110 supports the filament mesh structure 90. In some configurations, the platform 110 is configured as a table or workstation that supports the filament mesh structure 90 in a fixed position. In other configurations, the platform 110 is a conveyor that supports the filament mesh structure 90 and is configured to move the filament mesh structure 90. The platform 110 can include a water collector 120 that collects or receives a fluid, such as a liquid, ejected or sprayed by the cutting head 114. For example, the water collector 120 can be provided with the platform 110 or configured as a pan or tray positioned below the platform 110. The water collector 120 can be fluidly connected to the fluid supply subsystem 112, such as when the fluid is a liquid.

[0038] The fluid supply subsystem 112 supplies fluid to the cutting head 114. The fluid supply subsystem 112 includes a fluid source 130, a pump 132, and one or more fluid regulators 134.

[0039] The fluid source 130 contains or supplies a fluid. The fluid source 130 may be pressurized or non-pressurized. Examples of pressurized fluid sources include pressurized tanks, pressurized supply lines, etc. An example of a non-pressurized fluid source is an open tank or reservoir. In some configurations, the fluid source 130 receives fluid from the water collection device 120, allowing the fluid to be recycled or reused.

[0040] The pump 132 is fluidly connected or fluidly connectable to the fluid source 130 and the cutting head 114. The pump 132 increases the pressure of the fluid to facilitate delivery of the fluid to the cutting head 114.

[0041] One or more fluid regulators or fluid conditioning devices 134 , such as valves, are provided to control fluid flow, such as fluid flow from the fluid source 130 to the cutting head 114 .

[0042] The pump 132 and fluid regulator 134 may be controlled as described below to control the flow of fluid to the cutting head 114, for example, to allow or start fluid flow, stop fluid flow, control fluid pressure, control fluid flow rate, etc.

[0043] The cutting head 114 includes a nozzle 140 that provides a jet or stream of fluid. The jet or stream of fluid is configured to cut the filament 52 when directed at the filament 52 with sufficient pressure. The jet or stream of fluid may extend axially from an outlet or outlet orifice of the nozzle 140. The nozzle 140 is in fluid communication or fluid connection with the fluid supply subsystem 112 via a conduit, such as a hose or pipe. The cutting head 114 is attached to the automation 116.

[0044] The automation 116 is configured to position the cutting head 114. In some configurations, the automation 116 is a robotic arm, a robotic manipulator, or a linear actuator. The automation 116 may be a single-axis automation, a two-axis automation, a three-axis automation, or may have more than three axes to provide greater degrees of freedom for the automation's movement. For example, the automation 116 may have up to six degrees of freedom of movement, including translation in the X, Y, and Z (horizontal, vertical, depth) directions, and one or more degrees of freedom of movement in pitch, yaw, and roll rotation.

[0045] The automation 116 can hold the cutting head 114 in a stationary position relative to the filament mesh structure 90 or can move the cutting head 114 to facilitate cutting of the filament mesh structure 90. In one example, the automation 116 can include one or more actuators 150 configured to move the cutting head 114. For example, the actuators 150 can be configured to move the cutting head 114 along a linear path, such as when the automation 116 translates along an axis or in a plane, such as the XZ plane shown in FIG. 4. In other examples, the automation 116 can include one or more actuators 150 configured to move or cooperate to move the cutting head 114 in a complex path across the filament mesh structure 90, such as in a direction in a path including a non-linear path, a linear path, or a combination thereof in the XY plane, and / or to move the cutting head 114 vertically or in the YZ plane toward or away from the filament mesh structure 90 for automation with multiple degrees of freedom.

[0046] Additionally, the automation 116 can include additional actuators 150 that control the angle of the cutting head 114 relative to the filament mesh structure 90, allowing for rotation or tilt of the cutting head 114 relative to the X, Y, and Z axes or planes. Rotation or tilt of the cutting head 114 allows for angled cuts relative to the XY, YZ, and XZ planes, such as chamfers, angled slits, or V-shaped trenches.

[0047] In some configurations, the automation 116 has at least one support member that is fixed and extends across the filament mesh structure 90 and that moves one or more actuators 150 and the cutting head 114 relative to one another, for example, by sliding the cutting head 114 across or along the support member during movement.

[0048] The controller 118 monitors and controls the operation of the cutting system 100. The controller 118 includes one or more controllers or control modules, which may be distributed or centralized. Some or all of the controllers may be connected by a controller area network (CAN) or other system. The controller 118 communicates with various components of the cutting system, such as the platform 110 (e.g., pump 132 and fluid regulator 134), the fluid supply subsystem 112, and the automation 116.

[0049] The controller 118 receives inputs or input signals from sensors provided with the cutting system 100, such as proximity sensors, speed sensors, pressure sensors, flow sensors, etc., for use in controlling the cutting system 100. Additionally, the controller 118 can receive inputs from other systems in the manufacturing process or from users. In one example, the controller 118 receives an input indicative of the density of the filament mesh structure 90.

[0050] The controller 118 is configured to control the speed, including stopping, starting, and changing the direction of movement, of the platform 110, which is configured as a conveyor. As an example, the speed of the conveyor can be stopped or reduced when a cut is being made.

[0051] The controller 118 is configured to control the movement of the automation 116 by controlling its actuators 150 , and thus the position, orientation, and movement or transport speed of the cutting head 114 and nozzle 140 relative to the filament mesh structure 90 .

[0052] Controller 118 is configured to control the flow of fluid from nozzle 140, such as by controlling pump 132 and fluid regulator 134, to allow fluid flow to nozzle 140, increase fluid flow to nozzle 140, decrease fluid flow to nozzle 140, and stop fluid flow to nozzle 140. Controller 118 is configured to increase, decrease, or maintain the fluid pressure supplied to nozzle 140, the flow rate of fluid in nozzle 140, or both.

[0053] It will be appreciated that the controller 118 or other electrical devices disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., flash, random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variants thereof), and software that cooperate or work in conjunction with one another to perform the operations disclosed herein. Additionally, any one or more of the electrical devices disclosed herein may be configured to execute a computer program embodied in a non-transitory computer-readable medium that is programmed to perform any number of the functions disclosed herein.

[0054] The controller 118 is configured to control the speed of the cutting head 114 and the pressure and flow rate of the fluid exiting the nozzle 140 in response to the thickness of the filament mesh structure 90 and the selected depth of cut into the filament mesh structure 90. Additionally, the controller 118 can control the cutting head 114 and the cutting system 100 to provide a single pass cut or to provide a multi-pass cut where the selected cut requires multiple passes of the cutting head 114 along the cutting path.

[0055] The cutting system 100 can provide planar cuts, or cuts along a single plane aligned with or angled relative to the X, Y, and / or Z planes. Planar cuts can result in planar sides or surfaces of the filament mesh structure 90. Additionally, the cutting system 100 can provide cuts along a single axis.

[0056] The cutting system 100 can provide cuts across the filament mesh structure 90 to separate the filament mesh structure 90 into separate pieces, either with a single pass of the cutting head 114 over the filament mesh structure 90 or with multiple passes of the cutting head 114.

[0057] Additionally, the cutting system 100 is controllable in a manner that provides variable cut depths. Because the filaments 52 are bent, looped, or otherwise shaped in various directions with voids between them, the presence and location of the filaments 52 within the filament mesh structure 90 varies. Accordingly, the cutting system 100 is controllable to adjust the fluid jet depending on the presence, quantity, size, or absence of filaments 52 within the filament mesh structure 90 at the location where the cut is to be provided. For example, the cutting system 100 is controllable when cutting multiple filaments, when cutting larger diameter filaments, or to reach and cut filaments located at a greater depth or distance from the nozzle 140. For cuts, such as partial cuts that do not completely penetrate the filament mesh structure 90, the cutting system 100 can operate with additional passes of the cutting head 114 at lower speeds, lower fluid pressures, and / or lower fluid flow rates to increase the precision and / or accuracy of the cut into the filament mesh structure 90.

[0058] The cutting system 100 is configured to provide multiple types of cuts in the filament mesh structure 90. These include through cuts and partial cuts or "blind cuts" in the filament mesh structure 90. Through cuts can provide through holes or slits that separate the filament mesh structure 90 into separate pieces or do not result in separate pieces. Partial cuts do not extend completely through the filament mesh structure 90 and can be used to provide blind holes, trenches, slits, or slots. According to various examples, the cutting system 100 can be controlled to provide orthogonal cuts, bevels, fillets, radii, etc.

[0059] 5A-5G show views, which may be either side views or cross-sectional views, of a filament mesh structure (e.g., filament mesh structure 90) along with some examples of various cuts that can be provided by cutting system 100. These examples are not intended to be exhaustive. In these figures, filament mesh structure 90 is represented as a rectangular block prior to cutting. Dashed lines are used to represent the area of ​​the rectangular block that is cut.

[0060] FIG. 5A shows a vertical cut 160, which can produce orthogonal sides or orthogonal surfaces. FIG. 5B shows an undercut fillet 162. FIG. 5C shows a fillet 164. FIG. 5D shows a chamfer 166. FIG. 5E shows two partial cuts of different cut depths to form two trenches 168, which may be in a side view or cross section. FIG. 5F shows a through slot or through hole 170 and a blind hole 172 in a cross section. FIG. 5G shows a V-shaped channel 174, also referred to as a channel, recess, or slit, and an angled partial cut 176, which may be in a side view or cross section. The V-shaped channel 174 may have a greater depth and extend entirely through the filament mesh structure 90. The V-shaped channel 174 or the angled partial cut 176 is provided by performing two cuts, such as blind cuts, along different cutting paths that are angled and intersect with each other.

[0061] 6A and 6B show top views of a filament mesh structure (e.g., filament mesh structure 90) with various cuts that can be provided by cutting system 100. These examples are not exhaustive. FIG. 6A shows a double chamfer 178 and a trench 168 that are cut to a partial depth and extend laterally across filament mesh structure 90. FIG. 6B shows an example of a curved cut or curved profile 180. The curved sides can have convex sections, concave sections, or a combination thereof. FIG. 6B also shows an example of a through hole 170 and a trench 182 that has two angled sections connected by an arc-shaped portion and extends only partially across filament mesh structure 90, either a through cut or a partial cut.

[0062] It should be appreciated that the cutting system 100 can provide cuts along various sides of the filament mesh structure 90. Additionally, the cutting system 100 can provide through cuts and partial cuts in three dimensions, along linear and non-linear paths. For example, the cutting system 100 can provide curved or contoured surfaces when viewed along multiple axes, such as any combination of the X-axis, Y-axis, and Z-axis.

[0063] The controller 118 is configured to simultaneously control the movement of the automation 116 and the fluid flow and fluid pressure provided by the fluid delivery subsystem 112 to the nozzle 140 to provide a desired type of cut at a desired location. In some examples, a deeper cut may be provided by controlling the automation 116 to move the cutting head 114 at a slower speed, controlling the automation 116 to move the nozzle 140 closer to the filament mesh structure 90, controlling the automation 116 to move the nozzle 140 along multiple or repeating cutting passes, increasing the fluid flow rate to the nozzle 140, increasing the fluid flow rate to the nozzle 140, or a combination thereof. Similarly, a shallower cut may be provided by controlling the automation 116 to move the cutting head 114 at a faster speed, controlling the automation 116 to move the nozzle 140 further from the filament mesh structure 90, controlling the automation 116 to move the nozzle 140 along fewer cutting passes or no repeating cutting passes, decreasing the fluid flow rate to the nozzle 140, decreasing the fluid flow rate to the nozzle 140, or a combination thereof.

[0064] Control parameters associated with a particular type of cut can be based on experimentation or modeling. For example, a filament mesh structure 90 can be manufactured in the manufacturing system 60. Relevant filament parameters, such as the number of filaments extruded through the die 80, the size (e.g., cross-sectional area) of the filaments, and the extrusion rate of the filaments, are recorded. The density of the resulting filament mesh structure 90 is then measured and recorded, for example, by hydrostatic weighing. Sample cuts can then be performed in the cutting system 100 at various cutting head speeds, fluid pressures, and fluid flow rates to determine whether the combination of speed, pressure, and flow rate is sufficient to provide the desired cut in the filament mesh structure 90. The tolerance ranges or combinations of speed, pressure, and flow rate can be recorded or stored in memory and associated with the density of the filament mesh structure 90, since the density was previously measured. The tolerance ranges or combinations can then be input into or used by the controller 118 to control the cutting system 100 based on the density of the filament mesh structure 90.

[0065] As a non-limiting example, the nozzle 140 has a diameter of 8 thousandths of an inch and is operated at a distance of 5 mm to 10 mm from the filament mesh structure 90. The fluid jet is provided at a pressure in the range of 58,000 to 70,000 psi (399,895 to 482,633 kPa), and the nozzle has a velocity relative to the filament mesh structure 90 in the range of 1 to 75 mm / s. The fluid jet provides a through cut to the filament mesh structure 90 at a density in the range of 2.7 to 3.4 pounds per cubic foot (43.2 to 54.5 kg / m3) with a filament diameter of 0.5 mm. In other examples, each of the nozzle diameter, distance, nozzle velocity, pressure, and / or density or filament diameter of the filament mesh structure 90 may be greater or less than the recited ranges or values.

[0066] Multiple cutting systems 100, such as cutting systems arranged in parallel or series, can be used to increase throughput. Also, other cutting techniques, such as mechanical cutters, such as cut-off wheels, can be used in combination with the cutting system 100 to cut the filament mesh structure 90.

[0067] The method associated with cutting system 100 is used to form cushions (e.g., cushions 32 and / or 42) and, optionally, to assemble seats (e.g., seat assembly 10). In various examples, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0068] The method includes cutting a filament mesh structure (eg, filament mesh structure 90) with a fluid jet (eg, fluid jet 150).

[0069] In some embodiments, cutting a filament mesh structure (eg, filament mesh structure 90) with a fluid jet (eg, fluid jet 150) at least partially forms a cushion (eg, cushions 32 and / or 42).

[0070] In some embodiments, the method includes attaching a cushion (eg, cushion 32 and / or 42) to a frame (eg, frame 30 and / or 40) of a seat assembly (eg, seat assembly 10).

[0071] In some embodiments, the method includes positioning a trim cover (e.g., trim cover 34 and / or 44) over a cushion (e.g., cushion 32 and / or 42) and attaching the trim cover (e.g., trim cover 34 and / or 44) to the cushion (e.g., cushion 32 and / or 42), to the frame (e.g., frame 30 and / or 40), or to the cushion (e.g., cushion 32 and / or 42) and the frame (e.g., frame 30 and / or 40).

[0072] In some embodiments, the method includes forming a filament mesh structure (e.g., filament mesh structure 90) with filaments (e.g., filaments 52) of a thermoplastic material, wherein the filaments (e.g., filaments 52) are randomly looped and bonded.

[0073] In some embodiments, forming the filament mesh structure (e.g., filament mesh structure 90) includes extruding a thermoplastic material through a die (e.g., die 80) to form a filament (e.g., filament 52), and then passing the filament (e.g., filament 52) ​​through a funnel (e.g., funnel 74).

[0074] In some embodiments, the method includes cutting the filament mesh structure (eg, filament mesh structure 90) after the filament (eg, filament 52) ​​passes through a funnel (eg, funnel 74).

[0075] In some embodiments, the method includes controlling the speed of movement of a cutting head (e.g., cutting head 114) to control the depth of a cut (e.g., vertical cut 160, undercut fillet 162, fillet 164, chamfer 166, trench 168, through hole 170, blind hole 172, V-shaped channel 174, partial cut 176, chamfer 178, curved profile 180, trench 182) into the filament mesh structure (e.g., filament mesh structure 90).

[0076] In some embodiments, the method includes decreasing the speed of movement of a cutting head (e.g., cutting head 114) to increase the depth of a cut (e.g., vertical cut 160, undercut fillet 162, fillet 164, chamfer 166, trench 168, through hole 170, blind hole 172, V-shaped channel 174, partial cut 176, chamfer 178, curved profile 180, trench 182) into a filament mesh structure (e.g., filament mesh structure 90).

[0077] In some embodiments, the method includes moving a cutting head (e.g., cutting head 114) closer to the filament mesh structure (e.g., filament mesh structure 90) to increase the depth of a cut (e.g., vertical cut 160, undercut fillet 162, fillet 164, chamfer 166, trench 168, through hole 170, blind hole 172, V-shaped channel 174, partial cut 176, chamfer 178, curved profile 180, trench 182) into the filament mesh structure (e.g., filament mesh structure 90).

[0078] In some embodiments, the method includes increasing the fluid pressure supplied to a cutting head (e.g., cutting head 114) to increase the depth of a cut (e.g., vertical cut 160, undercut fillet 162, fillet 164, chamfer 166, trench 168, through hole 170, blind hole 172, V-shaped channel 174, partial cut 176, chamfer 178, curved profile 180, trench 182) into the filament mesh structure (e.g., filament mesh structure 90).

[0079] In some embodiments, the method includes increasing the fluid flow rate of a fluid jet (e.g., fluid jet 150) to increase the depth of a cut (e.g., vertical cut 160, undercut fillet 162, fillet 164, chamfer 166, trench 168, through hole 170, blind hole 172, V-shaped channel 174, partial cut 176, chamfer 178, curved profile 180, trench 182) into a filament mesh structure (e.g., filament mesh structure 90).

[0080] In some embodiments, cutting the filament mesh structure (e.g., filament mesh structure 90) with a fluid jet (e.g., fluid jet 150) includes positioning the cutting head (e.g., cutting head 114) away from the filament mesh structure (e.g., filament mesh structure 90) so that the cutting head (e.g., cutting head 114) does not contact the filament mesh structure (e.g., filament mesh structure 90).

[0081] In some embodiments, the method includes controlling an automation (e.g., automation 116) supporting a cutting head (e.g., cutting head 114) to move the cutting head (e.g., cutting head 114) along a cutting path relative to the filament mesh structure (e.g., filament mesh structure 90).

[0082] In some embodiments, the method includes controlling automation (eg, automation 116) in at least one degree of freedom to move a cutting head (eg, cutting head 114) along the cutting path.

[0083] In some embodiments, the method includes controlling automation (eg, automation 116) in at least three degrees of freedom to move a cutting head (eg, cutting head 114) along the cutting path.

[0084] In some embodiments, the method includes cutting an entire filament mesh structure (eg, filament mesh structure 90) via a fluid jet (eg, fluid jet 150).

[0085] In some embodiments, the method includes partially cutting a filament mesh structure (eg, filament mesh structure 90) via a fluid jet (eg, fluid jet 150).

[0086] In some embodiments, the method includes cutting one or more of a planar surface and a curved profile (e.g., curved profile 180) within a filament mesh structure (e.g., filament mesh structure 90) via a fluid jet (e.g., fluid jet 150).

[0087] In some embodiments, the method includes cutting one or more of an orthogonal surface (e.g., vertical cut 160), a fillet (e.g., undercut fillet 162, fillet 164), a chamfer (e.g., chamfer 166), and a trench (e.g., trench 168) in a filament mesh structure (e.g., filament mesh structure 90) via a fluid jet (e.g., fluid jet 150).

[0088] 7, an example of a forming system 200 for forming a filament mesh structure 90 is shown. The forming system 200 is configured to form or shape the filament mesh structure 90 without cutting or severing the filaments 52 of the filament mesh structure 90. The filament mesh structure 90 can be formed or shaped by the forming system 200 alone or in combination with the cutting system 100 described above.

[0089] As previously discussed, the manufacturing system 60 produces the filament mesh structure 90 having a particular cross-sectional shape, such as a rectangular cross-section. In some cases, the cross-sectional shape produced by the manufacturing system 60 does not provide a desired profile or seat cushion profile. Furthermore, the filaments 52 of the filament mesh structure 90 output from the manufacturing system 60 cool and harden such that the filaments 52 are relatively rigid, no longer in a plastic state, and therefore cannot be formed or shaped. Therefore, it may be desirable to modify the shape of the filament mesh structure 90 from its original cross-sectional profile (e.g., the cross-sectional profile produced by the manufacturing system 60) to provide one or more indentations, protruding regions, curved regions, etc. As an example, the filament mesh structure 90, or a portion thereof, may be heated and reshaped or reshaped to provide one or more indentations 210, an example of which is shown in FIG. 10 .

[0090] The recesses 210 provided in the filament mesh structure 90 may be elongated channels, holes, depressions, or trenches. The recesses 210 may be provided in any suitable location. For example, the recesses 210 may be provided on the sides of the filament mesh structure 90 that are configured to face the seat occupant. As some additional examples, the recesses 210 may be provided where the side bolsters contact the central seating portion of the filament mesh structure 90, the recesses 210 may extend across the central seating portion, such as front to back or left to right, or combinations thereof. The recesses 210 may be spaced apart from one another or may intersect. The recesses 210 may extend partially into the filament mesh structure 90 but not completely through it.

[0091] 7, there is shown an example of a molding system 200. The molding system 200 includes a support surface 220, a molding tool 222, a positioning device 224, a steam subsystem 226, and a control system 228.

[0092] The support surface 220 is configured to support the filament mesh structure 90. The support surface 220 may be a generally flat surface, as shown in FIG. 7. Alternatively, the support surface 220 may have a contour. The support surface 220 may be a fixed surface or a movable surface. The support surface 220 may be part of a forming die.

[0093] Shaping tool 222 facilitates the formation or shaping of filament mesh structure 90. More specifically, shaping tool 222 is configured to reshape filament mesh structure 90 to change or alter the shape or cross-section of filament mesh structure 90 in one or more locations. Shaping tool 222 is attached to positioning device 224.

[0094] The shaping tool 222 may be provided in a variety of configurations. These configurations are broadly categorized by the manner in which the shaping tool reshapes the filaments 52 of the filament mesh structure 90. For example, the shaping tool may reshape the filament mesh structure 90 by engaging the shaping tool with the filament mesh structure 90, by not engaging the shaping tool with the filament mesh structure 90, or by a combination thereof. FIGS. 7-10, 11, and 12 show examples of shaping tools 222, 222′ in which the shaping tool engages and applies force to at least a portion of the filaments 52 to reshape at least one filament 52 of the filament mesh structure 90. In the configuration shown in FIG. 13, the shaping tool 222″ does not engage and apply force to the filaments 52 to reshape the filament mesh structure 90. In each configuration, the shaping tool 222, 222′, 222″ includes one or more nozzles fluidly connected to the steam subsystem 226.

[0095] 7-10, a forming tool 222 is shown positioned over the filament mesh structure 90 and support surface 220. In FIGS. 7 and 8, the filament mesh structure 90 is shown in a speckled pattern representing a non-cross-section for clarity and simplicity. In FIGS. 9 and 10, the filaments of the filament mesh structure 90 are shown with randomly drawn lines to represent a cross-section of the filament mesh structure 90 so that the depressions 210 are more clearly visible. The forming tool 222 includes a tool body 230, a heater 232, one or more nozzles 234, one or more nozzle valves 236, or a combination thereof.

[0096] The tool body 230 provides the main structure of the forming tool 222. The tool body 230 is attachable to the positioning device 224 and includes or defines one or more passages 240 that fluidly connect the steam subsystem 226 to the nozzles 234 and nozzle valves 236. For example, the tool body 230 may include a manifold 242 from which the passages 240 may extend. The tool body 230 has a forming side 244.

[0097] Molded side 244 faces filament mesh structure 90 and support surface 220. In at least one configuration, molded side 244 includes one or more mold features 246. Molded features 246 are configured as protrusions extending toward filament mesh structure 90, indentations extending away from filament mesh structure 90, or a combination thereof. One or more nozzles 234 can include molded features 246.

[0098] The heater 232, if included, is configured to heat the forming side 244 of the forming tool 222. The heater 232 can have any suitable configuration. For example, the heater 232 can be configured as an electric or electrical resistance heater and can circulate a heated fluid through the tool body 230. The heater 232 can also be part of the vapor subsystem 226. For example, a heated fluid, such as steam or water, can be circulated within the tool body 230 before being delivered to one or more nozzles 234. The heat or thermal energy provided by the heater 232 to the forming side 244 increases the temperature of the forming features 246, which facilitates the modification or reformation of the filament 52, as discussed in more detail below.

[0099] One or more nozzles 234 are provided in the tool body 230. The nozzles 234 are fluidly connected to the steam subsystem 226 and direct pressurized steam 248 toward the filament mesh structure 90 to heat one or more filaments 52 in the filament mesh structure 90 and facilitate reforming or reforming the filaments 52, as discussed in more detail below. The nozzles 234 have at least one orifice through which the steam 248 can be discharged. The one or more nozzles 234 can include shaping features 246. In FIG. 7 , the nozzles 234 are shown positioned generally perpendicular to the top surface of the filament mesh structure 90 prior to reforming. However, the nozzles 234 may be positioned in a non-perpendicular relationship to the top surface of the filament mesh structure 90, or additional nozzles 234 or orifices may be provided that can be positioned in a non-perpendicular relationship to the top surface.

[0100] The nozzle valves 236 control flow to one or more associated nozzles 234. In the configuration shown in FIG. 7, each nozzle valve 236 is shown associated with a single nozzle 234. However, a nozzle valve 236 may be associated with multiple nozzles 234, and some or all of the nozzles 234 may not be fluidly connected to the nozzle valve 236. In some configurations, the nozzle valves 236 are provided with or within the tool body 230. The nozzle valves 236 are actuable between an open position and a closed position. In the open position, the nozzle valves 236 allow flow from the steam subsystem 226 through the nozzle valves 236 to one or more associated nozzles 234. In the closed position, the nozzle valves 236 prevent flow from the steam subsystem 226 through the nozzle valves 236 to one or more associated nozzles 234.

[0101] 11 and 12, another example of a forming tool 222′ is shown. In FIG. 11, the filament mesh structure 90 is shown in a speckled pattern representing a non-cross-sectional view for clarity and simplicity. In FIG. 12, the filaments of the filament mesh structure 90 are illustrated by randomly drawn lines to represent a cross-sectional view of the filament mesh structure. The forming tool 222′ can be positioned above the filament mesh structure 90 and can include a tool body 230′, a manifold 242′, and one or more nozzles 234.

[0102] The tool body 230' is fixedly positioned relative to the manifold 242', the nozzle 234, or both. In at least one configuration, the tool body 230' is positioned away from the nozzle 234 and does not contact the nozzle 234. The tool body 230' is moved or actuated by the positioning device 224. The tool body 230' is at least partially moved or actuated relative to the filament mesh structure 90 to apply pressure to reform one or more filaments 52, as described in more detail below. The tool body 230' can be configured as a wire, rod, or tube that extends completely or partially across the top surface of the filament mesh structure 90.

[0103] The manifold 242' fluidly connects the vapor subsystem 226 to the nozzles 234. For example, the manifold 242' can be configured as a tube or pipe that distributes fluid to the nozzles 234. Additionally, the manifold 242' can be positioned further from the top surface of the filament mesh structure 90 than at least a portion of the tool body 230' such that the manifold 242' and / or one or more of the nozzles 234 do not contact or engage the filaments 52 during reshaping.

[0104] One or more nozzles 234 are fluidly connected to the manifold 242'. One or more nozzle valves 236 may optionally be provided to control fluid flow to the one or more nozzles 234, as described above. The nozzles 234 may be spaced apart from one another and configured to provide steam 248 that heats the filament 52 and the tool body 230'.

[0105] Referring to FIG. 13, another example of a shaping tool 222″ is shown. The shaping tool 222″ is again shown positioned above the filament mesh structure 90. However, it should be understood that the shaping tool 222″ may be moved to other positions. The shaping tool 222″ may include one or more nozzles 234 and nozzle valves 236, as described above, but may omit a tool body that is engageable with the filament mesh structure 90.

[0106] Referring to FIG. 7 , a positioning device 224 positions the shaping tool 222 relative to the filament mesh structure 90. The positioning device 224 may have any suitable configuration. For example, the positioning device 224 may be a linear actuator configured to move the shaping tool 222 linearly or along an axis, such as between a retracted position and an extended position. In the retracted position, as shown in FIG. 7 , the shaping tool 222 is decoupled, remotely located, or spaced apart from the filament mesh structure 90. In the extended position, as shown in FIG. 9 , the shaping tool 222 engages and applies a force to the filament mesh structure 90. The positioning device 224 may also be provided in other configurations. For example, the positioning device may be configured to rotate the shaping tool 222 about an axis to engage or disengage with the filament mesh structure 90. As another example, the positioning device may be configured to move in multiple directions or have multiple degrees of freedom. An example of such a positioning device is shown in FIG. 13 , where the positioning device 224 is configured as a robotic manipulator with multiple degrees of freedom.

[0107] The steam subsystem 226 is configured to provide steam 248, or a fluid that becomes steam 248 when discharged from the nozzle 234, to the forming tool 222. As such, the term "steam" includes any combination of temperature and pressure that results in a vapor or evaporated fluid after exiting the nozzle. The term "steam" refers to evaporated water and evaporated fluids other than or in addition to water. The steam subsystem 226 has any suitable configuration. In at least one configuration, the steam subsystem 226 includes a fluid source 250, a fluid heater 252, and at least one control valve 254.

[0108] Fluid source 250 is configured to hold or supply a fluid, such as liquid water, that can be converted to steam 248. Fluid source 250 is fluidly connected to fluid heater 252 and control valve 254 in any suitable manner, such as by pipes, hoses, or the like.

[0109] Fluid heater 252 is fluidly connected to fluid source 250. Fluid heater 252 is configured to heat the liquid received from fluid source 250 so that the fluid becomes a gas or vapor 248 as it exits nozzle 234 or before it exits nozzle 234. For example, fluid heater 252 can heat the liquid so that it becomes a gas after passing through fluid heater 252 and before or after passing through control valve 254.

[0110] The control valve 254 controls the flow of fluid or gas to the molding tool 222. In at least one configuration, the control valve 254 is movable between an open position and a closed position. In the open position, the fluid or gas flows through the control valve 254 to the molding tool 222. In the closed position, the fluid or gas does not flow through the control valve 254.

[0111] Control system 228 monitors and controls the various components and subsystems of molding system 200. For example, control system 228 may include one or more microprocessor-based control modules or controllers 260 that can control the operation of molding tool 222, positioning device 224, steam subsystem 226, or a combination thereof. Thus, control system 228 controls the operation of positioning device 224, nozzle valve 236, fluid heater 252, control valve 254, or a combination thereof.

[0112] Referring to FIG. 16, a flowchart of a method of forming a filament mesh structure 90 is shown. This method may be associated with any of the molding system configurations previously described (e.g., molding system 200 using individual molding tools 222, 222′, 222″ or multiple molding tools 222, 222′, 222″ in any combination). The flowchart encompasses three main method steps. The method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0113] In block 300, filament mesh structure 90 and shaping tools 222, 222', and / or 222" are aligned such that shaping tools 222, 222', and / or 222" can reshape filament mesh structure 90 at one or more predetermined locations. Filament mesh structure 90 and shaping tools 222, 222', and / or 222" can be aligned by moving filament mesh structure 90 relative to shaping tools 222, 222', and / or 222", by moving shaping tools 222, 222', and / or 222" relative to filament mesh structure 90, or both.

[0114] In block 302, filament mesh structure 90 is formed by forming tools 222, 222', and / or 222". Filament mesh structure 90 is formed by forming tools 222, 222', and / or 222" by spraying steam 248 onto the filament mesh structure of filament mesh structure 90. Steam 248 may be sprayed directly onto filaments 52 or through an intermediate vapor-permeable layer such as a fabric or cloth. Spraying steam 248 onto the filament mesh structure serves multiple functions.

[0115] First, the steam 248 heats the filament 52, allowing it to be reshaped or reshaped. More specifically, the thermal energy provided by the steam 248 heats the thermoplastic filament 52 to a temperature that allows the thermoplastic material of the heated filament 52 to be reshaped into different shapes. The thermal energy softens or plasticizes the filament 52 without melting the filament 52. In this manner, the steam 248 is provided to maintain the temperature of the filament 52 below the melting temperature of the thermoplastic material. As an example, the filament 52 may be heated by the steam 248 to a temperature 10° C. to 50° C. below the melting temperature of the thermoplastic material. In this manner, the filament 52 is heated sufficiently to allow the filament 52 to be plastically reshaped, but insufficiently to form new bonds between one filament 52 and another filament 52 or between the filament 52 and itself.

[0116] Second, the vapor 248 provides a coating or barrier that helps prevent the filament 52 from adhering or sticking to the forming tools 222, 222′, and / or 222″. The coating may be a coating of fluid or droplets of fluid that accumulate on the exterior of the filament 52. The coating may act as a lubricant or barrier that is contacted by the forming tools 222, 222′, and / or 222″ and prevent the filament 52 from bonding to the forming tools 222, 222′, and / or 222″.

[0117] Third, in some circumstances, the steam 248 exerts sufficient pressure to reform one or more filaments 52 of the filament mesh structure 90 .

[0118] Different amounts of steam 248 may be supplied to different nozzles 234 to control the reformation of the filament mesh structure 90. For example, a first nozzle valve 236 controlling the flow of steam to a first nozzle 234 may be controlled to discharge a different amount of steam 248 than a second nozzle valve 236 controlling the flow of steam to a second nozzle 234.

[0119] At block 304, the flow of steam 248 is turned off and the positions of the shaping tools 222, 222′, and / or 222″ are reset to accommodate the reformation of another filament mesh structure 90. The flow of steam 248 may be turned off before resetting the positions of the shaping tools 222, 222′, and / or 222″, while the positions of the shaping tools 222, 222′, and / or 222″ are being reset, or after resetting the positions of the shaping tools 222, 222′, and / or 222″. Turning off the flow of steam 248 allows the temperature of the filament 52 to decrease so that it cannot be reshaped into a different shape without reheating.

[0120] More specific examples of method steps associated with different molding system configurations are now described.

[0121] 7, the forming tool 222 is shown in the stored position as previously described. The filament mesh structure 90 and forming tool 222 are aligned so that the forming tool 222 is ready to reshape the filament mesh structure 90 at one or more predetermined locations. The control valve 254, the nozzle valve 236, or both, are closed so that the steam 248 is not being sprayed by the nozzle 234. In configurations where the forming tool 222 includes a heater 232, the heater 232 can heat the forming tool 222 when the steam 248 is not being sprayed by the nozzle 234.

[0122] 8 , steam 248 is shown being sprayed by nozzle 234. Steam 248 is sprayed by nozzle 234 by opening control valve 254 and one or more nozzle valves 236, if provided. Steam 248 is directed at one or more filaments 52 of filament mesh structure 90 to heat the filaments 52 and help inhibit the filaments 52 from subsequently bonding to forming tool 222 as described above.

[0123] 9 , the shaping tool 222 engages the filament mesh structure 90. The shaping tool 222 engages the filament mesh structure 90 by moving the filament mesh structure 90, the shaping tool 222, or both, as described above. The movement of the shaping tool 222, the filament mesh structure 90, or both, can begin before the steam 248 is sprayed by the nozzle 234, after the steam 248 is sprayed by the nozzle 234, or simultaneously with the start of spraying the steam 248 by the nozzle 234. It is also contemplated that the shaping tool 222 may engage the filament mesh structure 90 before the steam 248 is sprayed by the nozzle 234, after the steam 248 is sprayed by the nozzle 234, or simultaneously with the start of spraying the steam 248 by the nozzle 234.

[0124] In the illustrated configuration, the shaping tool 222 engages the filament mesh structure 90 by moving the shaping tool 222 toward the filament mesh structure 90 with the positioning device 224. The filament mesh structure 90 and the shaping tool 222 are sectioned in FIG. 9 to better illustrate the shaping tool 222 engaging the filament mesh structure 90. The engagement of the shaping tool 222 with the filament mesh structure 90 causes the shaping tool 222 to exert a force on the filament 52 softened by the steam 248 and the optionally heated shaping tool 222. In response to this force, the softened filament 52 is reshaped by the shaping tool 222 and its shaping features 246. For example, the softened filament 52 may be reshaped or reformed around the shaping features 246, while other filaments 52 not engaged or not sufficiently heated by the shaping tool 222 may not be reshaped. Examples of the reshaping of the filament 52 are best illustrated with reference to FIGS. 14 and 15 .

[0125] In FIG. 14, an enlarged view of a portion of a filament mesh structure 90 is shown. A plurality of filaments 52 are shown in an initial configuration before being reshaped or reshaped. The initial configuration may be the configuration provided when the filament mesh structure 90 is first manufactured. For purposes of explanation, a location on one filament 52 is designated point A, and a location on another filament 52 is designated point B. Point A is spaced apart from and does not touch point B in FIG. 14.

[0126] In FIG. 15, an enlarged view of a portion of filament mesh structure 90 is shown after being reshaped or reformed by shaping tools 222, 222′, and / or 222″. Filament 52 including point A has been reshaped by shaping tools 222, 222′, and / or 222″ such that filament 52 including point A has moved downward from the perspective shown and into contact with filament 52 including point B. Although filament 52 including point A has been reshaped and moved into contact with filament 52 including point B, no new bonds have been formed between these filaments.

[0127] 9 , the shaping tool 222 engages or applies a force to the filament mesh structure 90 for a period of time sufficient to allow the filament 52 to reshape or reform. By way of example, the shaping tool 222 may engage the filament mesh structure 90 for approximately 1 to 10 seconds, although it is contemplated that the period may be less than 1 second if the filament 52 is sufficiently heated prior to engagement, or may be greater than 10 seconds if the filament 52 is not heated prior to engagement, etc.

[0128] 10 , the forming tool 222 is reset. The forming tool 222 is reset by manipulating the positioning device 224 to retract the forming tool 222 to the position shown in FIG. 7 . The flow of steam 248 through the nozzle 234 can be terminated before retracting the forming tool 222, after the forming tool 222 begins to retract, or simultaneously with the forming tool 222 beginning to retract. The flow of steam 248 is terminated by closing the nozzle valve 236, the control valve 254, or both. Turning off the flow of steam 248 before raising the forming tool 222 can reduce energy consumption and can help avoid continued heating of the filament 52 and the potential for excessive softening or melting of the filament 52.

[0129] 11 and 12 are similar to the steps associated with the configurations shown in FIGS. 7-10. For example, the forming tool 222′ can start in a retracted position with one or more valves, such as the control valve 254 and / or the nozzle valve 236, closed so that the steam 248 is not sprayed by the nozzle 234. One or more valves are opened so that the steam 248 is sprayed by the nozzle 234. The steam 248 is directed to a location on the filament mesh structure 90 where the forming tool 222′ engages the filament mesh structure 90. Optionally, a portion of the steam 248 can be directed toward the forming tool 222′ to heat the forming tool 222′. The steam 248 heats the filament 52 and inhibits bonding of the filament 52 to the forming tool 222′, as described above.

[0130] The shaping tool 222 engages the filament mesh structure 90 by moving the shaping tool 222′, the filament mesh structure 90, or both. Engagement of the shaping tool 222′ with the filament mesh structure 90 causes the shaping tool 222′ to exert a force on the filaments 52 softened by the steam 248 and optionally softened by the heated shaping tool 222′. As a result, the softened filaments 52 are reformed by the shaping tool 222′. For example, the softened filaments 52 may be reformed or reshaped around the shaping feature 246′, while other filaments 52 not engaged by the shaping tool 222′ or the reformed filaments 52 are not reformed. The shaping tool 222′ may engage the filament mesh structure 90 for a period of time sufficient to allow the filaments 52 to be reformed or reshaped as described above. Finally, the shaping tool 222′ may be reset by operating the positioning device 224 and terminating the flow of steam 248 through the nozzle 234.

[0131] The shaping tool 222' is shown in Figures 11 and 12 as having a circular cross-section. However, it should be understood that the shaping tool 222' may have a non-circular cross-section or a combination of circular and non-circular cross-sections. For example, a shaping tool 222' having a V-shaped cross-section may form a V-shaped channel 174, as shown in Figure 5G. Similarly, the shaping tool 222' in Figures 11 and 12 is shown as having a straight or linear shape. However, it is contemplated that the shaping tool 222' may have a curved or non-linear shape, or a combination of straight and curved segments or straight and non-linear segments.

[0132] A method associated with molding system 200 according to some embodiments is directed to forming a filament mesh structure, such as filament mesh structure 90. In various embodiments, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0133] The method includes spraying steam (e.g., steam 248) onto a filament mesh structure (e.g., filament mesh structure 90), the filament mesh structure (e.g., filament mesh structure 90) including filaments (e.g., filaments 52) of a thermoplastic material, the filaments (e.g., filaments 52) being randomly looped and bonded, and heating at least a portion of the filaments (e.g., filaments 52) by spraying the steam (e.g., steam 248).

[0134] The method includes engaging a shaping tool (e.g., shaping tool 222 and / or 222′) with a filament (e.g., filament 52) ​​heated by steam (e.g., steam 248), and by engaging the shaping tool (e.g., shaping tool 222 and / or 222′), reforming a filament mesh structure (e.g., filament mesh structure 90).

[0135] In some embodiments, the filament (eg, filament 52) ​​is heated by steam (eg, steam 248) to a temperature below the melting temperature of the thermoplastic material.

[0136] In some embodiments, steam (e.g., steam 248) is sprayed onto the filament mesh structure (e.g., filament mesh structure 90) before engaging a shaping tool (e.g., shaping tool 222 and / or 222′) with the filament (e.g., filament 52).

[0137] In some embodiments, when a vapor (eg, vapor 248) is sprayed onto the filament mesh structure (eg, filament mesh structure 90), a liquid coating accumulates on the filaments (eg, filaments 52).

[0138] In some embodiments, the shaping tool (eg, shaping tool 222 and / or 222') contacts the liquid coating.

[0139] In some embodiments, the shaping tool (eg, shaping tool 222 and / or 222') is heated before the shaping tool (eg, shaping tool 222 and / or 222') engages the filament (eg, filament 52).

[0140] In some embodiments, steam (eg, steam 248) heats a shaping tool (eg, shaping tool 222 and / or 222') while the shaping tool is engaged with a filament (eg, filament 52).

[0141] In some embodiments, spraying the vapor (e.g., vapor 248) includes spraying the vapor (e.g., vapor 248) using a first nozzle (e.g., nozzle 234) and a second nozzle (e.g., nozzle 234), wherein a first nozzle valve (e.g., nozzle valve 236) controls the flow of the vapor (e.g., vapor 248) to the first nozzle (e.g., nozzle 234), a second nozzle valve (e.g., nozzle valve 236) controls the flow of the vapor (e.g., vapor 248) to the second nozzle (e.g., nozzle 234), and an amount of the vapor (e.g., vapor 248) supplied to the first nozzle (e.g., nozzle 234) using the first nozzle valve (e.g., nozzle valve 236) is different from an amount of the vapor (e.g., vapor 248) supplied to the second nozzle (e.g., nozzle 234) using the second nozzle valve (e.g., nozzle valve 236).

[0142] In some embodiments, terminating the spraying of steam (e.g., steam 248) and detaching the shaping tool (e.g., shaping tool 222 and / or 222′) from the filament mesh structure (e.g., filament mesh structure 90) occurs after the filament mesh structure (e.g., filament mesh structure 90) is reformed.

[0143] In some embodiments, the steam (e.g., steam 248) heats the shaping tool (e.g., shaping tool 222 and / or 222′) before the shaping tool (e.g., shaping tool 222 and / or 222′) engages the filament (e.g., filament 52) ​​and heats the shaping tool (e.g., shaping tool 222 and / or 222′) while the shaping tool (e.g., shaping tool 222 and / or 222′) engages the filament (e.g., filament 52).

[0144] In some embodiments, spraying the steam (e.g., steam 248) includes spraying the steam (e.g., steam 248) with a molding tool (e.g., molding tool 222 and / or 222'), the molding tool (e.g., molding tool 222 and / or 222') including one or more nozzles (e.g., nozzle 234) fluidly connected to a manifold (e.g., 242 and / or 242') and a tool body (e.g., tool body 230 and / or 230') fixedly positioned relative to the plurality of nozzles (e.g., nozzle 234).

[0145] In some embodiments, the plurality of nozzles (eg, nozzle 234) do not contact the filament (eg, filament 52) ​​when spraying the vapor (eg, vapor 248).

[0146] In some embodiments, engaging a shaping tool (e.g., shaping tool 222 and / or 222′) with a filament (e.g., filament 52) ​​includes actuating a tool body (e.g., tool body 230 and / or 230′) at least partially within the filament mesh structure (e.g., filament mesh structure 90) to apply pressure to reform the filament mesh structure (e.g., filament mesh structure 90).

[0147] In some embodiments, the plurality of nozzles (e.g., nozzle 234) are spaced apart from the filament mesh structure (e.g., filament mesh structure 90) when the tool body (e.g., tool body 230') is actuated at least partially into the filament mesh structure (e.g., filament mesh structure 90).

[0148] Referring to FIG. 13 , force is exerted by steam 248 to reform the filament 52, rather than by engagement of the shaping tool 222″ with the filament 52. The method steps associated with this configuration are similar to those described above. First, the filament mesh structure 90 and the shaping tool 222″ are aligned such that the shaping tool 222″ is positioned to reform the filament mesh structure 90 in one or more predetermined configurations. Next, steam 248 is sprayed through one or more nozzles 234. The steam 248 may be sprayed through the nozzles 234 by opening a control valve 254 and one or more nozzle valves 236, if present. The steam 248 is directed at one or more filaments 52 of the filament mesh structure 90 in a sufficient amount or for a sufficient period of time to heat the filament 52 so that it can reform or reshape. The filament 52 is reformed by the pressure exerted by the steam 248, rather than by contact with, engagement with, or application of force directly to the filament 52 with the shaping tool 222″.

[0149] The force exerted by the steam 248 on one or more filaments 52 is controlled by the control system 228 by controlling the position of the nozzle 234, controlling the movement of the nozzle 234, controlling the flow (e.g., flow rate) of the steam 248 through one or more nozzles 234, controlling the amount of time the steam 248 is applied to the filament 52, controlling the number of nozzles or nozzle orifices spraying the steam 248 toward the filament 52, or a combination thereof. For example, the amount of force exerted by the steam 248 can be increased by opening the nozzle valve 236 wider to increase the steam flow rate and the amount of force exerted, holding the nozzle 234 over the filament 52 for a longer period of time, applying force to the filament 52 with steam from more nozzles 234, moving the nozzle 234 closer to the filament 52 to increase the amount of steam 248 pressing against the filament 52 (instead of spraying over or against another filament 52), or a combination thereof. Increasing the amount of force exerted on the filament 52 can cause greater movement of the filament and can form deeper or wider depressions in the filament mesh structure 90.

[0150] Conversely, the amount of force exerted by the steam 248 can be reduced by closing the valve, opening the nozzle valves 236 less to reduce the steam flow rate and the amount of force exerted, holding the nozzles 234 over the filament 52 for a shorter period of time, applying force to the filament 52 with steam from fewer nozzles 234, moving the nozzles 234 further away from the filament 52 to reduce the amount of steam 248 pressing against the filament 52, or a combination thereof. Reducing the amount of force exerted on the filament can reduce filament movement and form shallower or narrower depressions in the filament mesh structure 90. The pressure exerted by the steam can be varied as the shaping tool 222″ moves.

[0151] In some configurations, the nozzle 234 is moved by the positioning device 224″ while spraying the steam 248 such that the steam 248 heats and reshapes additional filaments 52 of the filament mesh structure 90. As a result, the path of movement of the nozzle 234 can be used to form various contour features in the filament mesh structure 90 without contacting the filament mesh structure 90. The flow of steam 248 is interrupted or temporarily blocked when the nozzle 234 moves over an area of ​​the filament mesh structure 90 that is not to be reshaped.

[0152] A method associated with molding system 200 according to some embodiments is directed to forming a filament mesh structure, such as filament mesh structure 90. In various examples, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0153] The method includes spraying steam (e.g., steam 248) onto a filament mesh structure (e.g., filament mesh structure 90) using a shaping tool (e.g., shaping tool 222"), the filament mesh structure (e.g., filament mesh structure 90) being comprised of randomly looped and bonded filaments (e.g., filaments 52) of a thermoplastic material, the shaping tool (e.g., shaping tool 222") having a nozzle (e.g., nozzle 234) for spraying the steam (e.g., steam 248), the steam (e.g., steam 248) heating and applying pressure to at least a portion of the filaments (e.g., filaments 52) reforming the filament mesh structure (e.g., filament mesh structure 90), and the shaping tool (e.g., shaping tool 222") not engaging the filament mesh structure (e.g., filament mesh structure 90).

[0154] In some embodiments, reforming the filament mesh structure (e.g., filament mesh structure 90) includes moving a nozzle (e.g., nozzle 234) relative to the filament mesh structure (e.g., filament mesh structure 90) while spraying steam (e.g., steam 248).

[0155] In some embodiments, moving a nozzle (e.g., nozzle 234) while spraying steam (e.g., steam 248) heats and reforms additional filaments (e.g., filament 52) ​​of the filament mesh structure (e.g., filament mesh structure 90).

[0156] In some embodiments, the vapor (eg, vapor 248) is sprayed directly onto the filament mesh structure (eg, filament mesh structure 90).

[0157] In some embodiments, the pressure exerted by the steam (eg, steam 248) varies as the shaping tool (eg, shaping tool 222") is moved.

[0158] In some embodiments, a shaping tool (eg, shaping tool 222") is positioned on a positioning device (eg, positioning device 224").

[0159] By heating the filaments with steam or the like, the filament mesh structure 90 can be reshaped after its initial manufacture. In this manner, the filament mesh structure 90 can be reshaped from its initial configuration to another configuration that is more suitable for seating applications, improving seat occupant comfort. Reshaping is accomplished without cutting or removing material from the filament mesh structure 90, thereby reducing or eliminating material removal operations and reducing waste. Reshaping can be achieved using steam rather than using chemicals or softeners. Additionally, steam can prevent the filaments from adhering to the shaping tool without the use of oils or other conventional lubricants, thereby reducing costs and allowing the filament mesh structure to be quickly reshaped into a desired shape.

[0160] 17-23, another example of a cushion (e.g., cushion 50) is shown. In this example, the cushion's filament mesh structure 90 is folded to create a desired shape. The folding can be facilitated by forming recesses or trenches in the filament mesh structure 90 using the cutting system 100 or shaping system 200 described above. FIGS. 17-22 are grouped in pairs, with the even-numbered figures being top views and the odd-numbered figures being side views.

[0161] 17 and 18, a section or block of filament mesh structure 90 that can be manufactured by manufacturing system 60 is shown. For simplicity, filament mesh structure 90 is shown as having a generally rectangular shape and a rectangular cross-section. Filament mesh structure 90 has multiple sides, including a first side 400, a second side 402, a third side 404, and a fourth side 406. In this example, first side 400 is disposed opposite second side 402, and third side 404 is disposed opposite fourth side 406. Third side 404 may be the front side, and fourth side 406 may be the back side. Filament mesh structure 90 may also include a first lateral side 408 and a second lateral side 410 disposed opposite first lateral side 408.

[0162] 19 and 20, blocks of filament mesh structure 90 are shown after being formed to provide different shapes. Filament mesh structure 90 may be formed by removing material using cutting system 100, by shaping or reshaping the filaments of filament mesh structure 90 using shaping system 200, or both. It is also contemplated that filament mesh structure 90 may be formed in a die to shape or reshape the filaments.

[0163] In Figure 19, the perimeter of filament mesh structure 90, when viewed from above, is shown with a curved or contoured shape, as is evident by comparing Figures 17 and 18 with Figures 19 and 20. The curved or contoured shape can include shaping or removing material from one or more sides of filament mesh structure 90. In Figures 19 and 20, filament mesh structure 90 is shown with multiple trenches, such as first trench 420, second trench 422, third trench 424, and fourth trench 426. These trenches can have linear or non-linear configurations.

[0164] A first trench 420 and a second trench 422 are shown formed in the first side 400 and extending partially toward the second side 402. The first trench 420 and the second trench 422 are shown extending from the third side 404 to the fourth side 406.

[0165] The portion of the filament mesh structure 90 disposed between the bottom of the first trench 420 and the second side 402 is referred to as the first foldable connecting segment 430. The first foldable connecting segment 430 includes a filament 52 connecting a first portion 440 of the filament mesh structure 90 to a second portion 442 of the filament mesh structure 90 disposed on the opposite side of the first trench 420 from the first portion 440. In the illustrated configuration, the first portion 440 is a central or central seating portion of the filament mesh structure 90. The first foldable connecting segment 430 can have a linear configuration, a non-linear configuration, or a combination thereof. In the illustrated configuration, the first foldable connecting segment 430 is linear.

[0166] The portion of the filament mesh structure 90 disposed between the bottom of the second trench 422 and the second side 402 is referred to as the second foldable connecting segment 432. The second foldable connecting segment 432 includes a filament 52 connecting a first portion 440 of the filament mesh structure 90 to a third portion 444 of the filament mesh structure 90 disposed on the opposite side of the second trench 422 from the first portion 440. The second foldable connecting segment 432 can have a linear configuration, a non-linear configuration, or a combination thereof. In the illustrated configuration, the second foldable connecting segment 432 is linear.

[0167] The first trench 420 and the second trench 422 can have any suitable cross-sectional shape. In the illustrated configuration, the first trench 420 and the second trench 422 are shown in a generally V-shaped or slit-like configuration.

[0168] 19 , third trench 424 and fourth trench 426, if present, are shown formed in second side 402 and extending partially through filament mesh structure 90 toward first side 400. Optionally, third trench 424 and fourth trench 426 can extend into first foldable connecting segment 430, second foldable connecting segment 432, or both.

[0169] It should be understood that the filament mesh structure 90 may be inverted or flipped from the position shown in Figures 19 and 20 when the filament mesh structure is being formed. For example, the filament mesh structure 90 may be positioned with the first side 400 facing upward for easier access by the cutting system 100, the forming system 200, or both.

[0170] 21 and 22, the filament mesh structure 90 is shown after folding the filament mesh structure 90 along the first foldable connecting segment 430 and the second foldable connecting segment 432.

[0171] In some configurations, folding the second portion 442 along the first foldable connecting segment 430 positions the second portion 442 on the first portion 440. Folding the second portion 442 over the first portion 440 may position the second portion 442 so that it contacts the first portion 440. For example, folding the second portion 442 along the first foldable connecting segment 430 may fold back the portion of the second side 402 where the second portion 442 is provided and rotate the second portion 442 relative to the first portion 440 so that it contacts the portion of the second side 402 where the first portion 440 is provided. Folding the second portion 442 in this manner may create a seat cushion (e.g., cushions 32 and / or 42) in which the second portion 442 forms a first side bolster.

[0172] In some configurations, folding the third portion 444 along the second foldable connecting segment 432 positions the third portion 444 on the first portion 440. Folding the third portion 444 along the first portion 440 may position the third portion 444 so that it contacts the first portion 440. For example, folding the third portion 444 along the second foldable connecting segment 432 may fold back the portion of the second side 402 where the third portion 444 is provided and rotate the third portion 444 relative to the first portion 440 so that it contacts the portion of the second side 402 where the first portion 440 is provided. Folding the third portion 444 in this manner may create a seat cushion (e.g., cushion 32 and / or 42) in which the third portion 444 forms a second side bolster.

[0173] While first portion 440 and second portion 442 are shown rotated upward, this is not intended to be limiting, as the foldable portions may be rotated in any suitable direction based on the position of the trenches and associated foldable connecting segments. Additionally, the foldable portions may be folded a smaller angular distance in some configurations. For example, they may be folded so that opposite sides of the V-shaped slits engage with each other.

[0174] Referring to FIG. 23 , the folded portions are secured. For example, the second portion 442 is secured to the first portion 440 after folding the second portion 442, thereby holding the second portion 442 in its folded position. Similarly, the third portion 444 is secured to the first portion 440 after folding the third portion 444, thereby holding the third portion 444 in its folded position. The securing of the folded portions is represented by attachment marks 450 in FIG. 23 . The folded portions, such as the second portion 442 or the third portion 444, can be secured in any suitable manner. For example, the attachment marks 450 can represent attachment by chemical or adhesive bonding with a mechanical fastener such as a clip, ring, hook-and-loop fastener, clamp, etc., or by directly bonding one or more filaments 52 of the folded portion to the first portion 440 by heat bonding or melting one or more filaments 52 so that new attachment points are formed on the filaments 52. It is also contemplated that the folded portions may not be secured.

[0175] It should be appreciated that trenches or foldable connecting segments can be provided on opposite sides of filament mesh structure 90 to allow filament mesh structure 90 to fold in different directions. Thus, different portions of the cushion may be folded in different planes, along different axes, or along different sides of filament mesh structure 90.

[0176] It should also be understood that a cushion (e.g., cushion 50) may be provided by stacking multiple layers of filament mesh structure 90, and one or more layers may not include foldable connecting segments. For example, foldable connecting segments may be provided on the top filament mesh structure layer, but not on other layers disposed below or behind the top filament mesh structure layer. It should also be understood that layers may be stacked laterally rather than vertically.

[0177] The cushion (e.g., cushion 32 and / or 42) includes a filament mesh structure (e.g., filament mesh structure 90) including filaments (e.g., filaments 52) of a thermoplastic material, the filaments (e.g., filaments 52) being randomly looped and bonded, the filament mesh structure (e.g., filament mesh structure 90) having trenches (e.g., trenches 168, 420, and / or 422) extending from a first side (e.g., first side 400) of the filament mesh structure (e.g., filament mesh structure 90) toward a second side (e.g., second side 402) of the filament mesh structure (e.g., filament mesh structure 90), the second side (e.g., second side 402) having a trench (e.g., trench 168, 420, and / or 422) extending from a first side (e.g., first side 400) of the filament mesh structure (e.g., filament mesh structure 90) toward a second side (e.g., second side 402) of the filament mesh structure (e.g., filament mesh structure 90), the second side (e.g., second side 402) having a The trench (e.g., trench 168, and / or 420, and / or 422) and the second side (e.g., second side 402) are arranged opposite the first side (e.g., first side 400), and cooperate to form a foldable connecting segment (e.g., foldable connecting segment 430) therebetween, and the foldable connecting segment (e.g., foldable connecting segment 430) connects a first portion (e.g., first portion 440) of the filament mesh structure (e.g., filament mesh structure 90) to a second portion (e.g., second portion 442) of the filament mesh structure (e.g., filament mesh structure 90), and the second portion (e.g., second portion 442) is folded over the first portion (e.g., first portion 440).

[0178] In some embodiments, the second side (e.g., second side 402) of the first portion (e.g., first portion 440) contacts the second side (e.g., second side 402) of the second portion (e.g., second portion 442).

[0179] In some embodiments, a first portion (eg, first portion 440) is secured to a second portion (eg, second portion 442).

[0180] In some embodiments, the cushion (eg, cushion 32 and / or 42) is a seat cushion.

[0181] In some embodiments, the second portion (eg, second portion 442) is a side bolster of the cushion (eg, cushions 32 and / or 42).

[0182] In some embodiments, the first portion (eg, first portion 440) at least partially defines a central seating portion of the cushion (eg, cushions 32 and / or 42).

[0183] The method according to some embodiments is directed to manufacturing a cushion, such as cushion 32 and / or 42. In various embodiments, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0184] The method includes forming a trench (e.g., trench 168, and / or 420, and / or 422) in a filament mesh structure (e.g., filament mesh structure 90) extending from a first side (e.g., first side 400) of the filament mesh structure (e.g., filament mesh structure 90) toward a second side (e.g., second side 402) of the filament mesh structure (e.g., filament mesh structure 90) that is different from the first side (e.g., first side 400), the trench (e.g., trench 168, and / or 420, and / or 422) and the second side (e.g., second side 402) cooperating to define a foldable connection segment (e.g., foldable connection segment 430) therebetween, and folding the filament mesh structure (e.g., filament mesh structure 90) along the foldable connection segment (e.g., foldable connection segment 430) therebetween.

[0185] In some embodiments, the foldable connecting segment (eg, foldable connecting segment 430) is linear.

[0186] In some embodiments, the foldable connection segment (e.g., foldable connection segment 430) extends from a third side (e.g., third side 404) of the filament mesh structure (e.g., filament mesh structure 90) to a fourth side (e.g., fourth side 406) of the filament mesh structure (e.g., filament mesh structure 90) that is different from the third side (e.g., third side 404).

[0187] In some embodiments, the third side extends from the first side (eg, first side 400) to the second side (eg, second side 402).

[0188] In some embodiments, the fourth side (eg, fourth side 406) extends from the first side (eg, first side 400) to the second side (eg, second side 402).

[0189] In some embodiments, a first side (e.g., first side 400) is disposed opposite a second side (e.g., second side 402), and a third side (e.g., third side 404) is disposed opposite a fourth side (e.g., fourth side 406).

[0190] In some embodiments, a foldable connection segment (e.g., foldable connection segment 430) connects a first portion (e.g., first portion 440) of a filament mesh structure (e.g., filament mesh structure 90) to a second portion (e.g., second portion 442) of the filament mesh structure (e.g., filament mesh structure 90), and folding the filament mesh structure (e.g., filament mesh structure 90) along the foldable connection segment (e.g., foldable connection segment 430) includes folding the second portion (e.g., second portion 442) over the first portion (e.g., first portion 440).

[0191] In some embodiments, folding the second portion (e.g., second portion 442) over the first portion (e.g., first portion 440) includes folding the second portion (e.g., second portion 442) into contact with the first portion (e.g., first portion 440).

[0192] In some embodiments, the second portion (e.g., second portion 442) is secured to the first portion (e.g., first portion 440) after folding the second portion (e.g., second portion 442), thereby holding the second portion (e.g., second portion 442) in the folded position.

[0193] In some embodiments, securing the second portion (e.g., second portion 442) to the first portion (e.g., first portion 440) comprises bonding the first portion (e.g., first portion 440) to the second portion (e.g., second portion 442).

[0194] In some embodiments, securing the second portion (e.g., second portion 442) to the first portion (e.g., first portion 440) includes attaching the first portion (e.g., first portion 440) to the second portion (e.g., second portion 442) with a fastener.

[0195] In some embodiments, forming trenches (eg, trenches 420 and / or 422) in a filament mesh structure (eg, filament mesh structure 90) includes cutting the filament mesh structure (eg, filament mesh structure 90).

[0196] Clause 1. A method comprising cutting a filament mesh structure via a fluid jet.

[0197] Clause 2. The method of clause 1, wherein the cushion is formed at least in part by cutting a filament mesh structure with a fluid jet.

[0198] Clause 3. The method of clause 2, further comprising attaching the cushion to a frame of the seat assembly.

[0199] Clause 4. The method of clause 3, further comprising placing a trim cover over the cushion and attaching the trim cover to the cushion, the frame, or the cushion and the frame.

[0200] Clause 5. The method of any of clauses 1-4, further comprising forming a filament mesh structure from filaments of a thermoplastic material, the filaments being randomly looped and bonded.

[0201] Clause 6. The method of clause 5, wherein forming the filament mesh structure includes extruding a thermoplastic material through a die to form filaments, and then passing the filaments through a funnel.

[0202] Clause 7. The method of clause 6, further comprising cutting the filament mesh structure after the filaments pass through the funnel.

[0203] Clause 8. The method of any of clauses 1 to 7, further comprising controlling the speed of movement of the cutting head to control the depth of cuts into the filament mesh structure.

[0204] Clause 9. The method of clause 8, further comprising decreasing the speed of movement of the cutting head to increase the depth of cut.

[0205] Clause 10. The method of clause 8 or 9, further comprising bringing the cutting head closer to the filament mesh structure to increase the depth of the cut.

[0206] Clause 11. The method of any of clauses 8-10, further comprising increasing the fluid pressure supplied to the cutting head to increase the depth of the cut.

[0207] Clause 12. The method of any of clauses 8-11, further comprising increasing the fluid flow rate of the fluid jet to increase the depth of cut.

[0208] Clause 13. The method of any of clauses 8 to 13, wherein cutting the filament mesh structure with the fluid jet includes positioning the cutting head at a distance from the filament mesh structure such that the cutting head does not contact the filament mesh structure.

[0209] Clause 14. The method of any of clauses 8-13, further comprising controlling an automated device supporting the cutting head to move the cutting head along a cutting path relative to the filament mesh structure.

[0210] Clause 15. The method of clause 14, further comprising controlling an automated device in at least one degree of freedom to move the cutting head along the cutting path.

[0211] Clause 16. The method of clause 14, further comprising controlling an automated device in at least three degrees of freedom to move the cutting head along the cutting path.

[0212] Clause 17. The method of any of clauses 1-16, further comprising cutting the entire filament mesh structure via a fluid jet.

[0213] Clause 18. The method of any of clauses 1-17, further comprising partially cutting the entire filament mesh structure via a fluid jet.

[0214] Clause 19. The method of any of clauses 1-18, further comprising cutting one or more of flat and curved contours in the filament mesh structure via a fluid jet.

[0215] Clause 20. The method of any of clauses 1-19, further comprising cutting one or more of orthogonal faces, fillets, chamfers, and trenches in the filament mesh structure via a fluid jet.

[0216] Clause 21. A method of forming a filament mesh structure, the method comprising: spraying steam onto the filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and bonded, the sprayed steam heating at least a portion of the filaments; engaging the filaments heated by the steam with a forming tool; and reforming the filament mesh structure by engaging the forming tool.

[0217] Clause 22. The method of clause 21, wherein the filaments are heated by steam to a temperature below the melting temperature of the thermoplastic material.

[0218] Clause 23. The method of clause 21 or 22, wherein steam is sprayed onto the filament mesh structure prior to engaging the forming tool with the filament mesh structure.

[0219] Clause 24. The method of any of clauses 21-23, wherein a liquid coating builds up on the filaments when steam is sprayed onto the filament mesh structure.

[0220] Clause 25. The method of any of clauses 24, wherein the shaped tool contacts the liquid coating.

[0221] Clause 26. The method of any of clauses 21-25, wherein the shaping tool is heated before the shaping tool engages the filament.

[0222] Clause 27. The method of any of clauses 21-26, wherein the steam heats the shaping tool while the shaping tool is engaged with the filament.

[0223] Clause 28. The method of any of clauses 21 to 27, wherein spraying the steam includes spraying the steam through a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, and a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam supplied to the first nozzle by the first nozzle valve is different from an amount of steam supplied to the second nozzle by the second nozzle valve.

[0224] Clause 29. The method of any of clauses 21-28, further comprising terminating the spray of steam after reforming the filament mesh structure and separating the forming tool from the filament mesh structure.

[0225] Clause 30. The method of any of clauses 21-29, wherein the steam heats the shaping tool before the shaping tool engages the filament and heats the shaping tool while the shaping tool engages the filament.

[0226] Clause 31. The method of any of clauses 21-30, wherein spraying the steam includes spraying the steam with a forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0227] Clause 32. The method of clause 31, wherein the plurality of nozzles do not contact the filament when spraying the steam.

[0228] Clause 33. The method of clause 31 or 32, wherein engaging the shaping tool with the filament includes applying pressure to at least partially actuate the tool body into the filament mesh structure to reshape the filament mesh structure.

[0229] Clause 34. The method of any of clauses 31-33, wherein the plurality of nozzles are positioned away from the filament mesh structure when the tool body is actuated at least partially into the filament mesh structure.

[0230] Clause 35. A method of forming a filament mesh structure, the method comprising: spraying steam onto the filament mesh structure with a forming tool, the filament mesh structure being comprised of randomly looped and bonded filaments of a thermoplastic material, the forming tool having a nozzle for spraying steam, the steam heating and applying pressure to at least a portion of the filaments reforming the filament mesh structure, the forming tool not engaging the filament mesh structure.

[0231] Clause 36. The method of clause 35, wherein reforming the filament mesh structure includes moving a nozzle relative to the filament mesh structure while spraying steam.

[0232] Clause 37. The method of clause 36, wherein additional filaments of the filament mesh structure are heated and reformed by moving the nozzle while spraying steam.

[0233] Clause 38. The method of any of clauses 35 to 37, wherein steam is sprayed directly onto the filament mesh structure.

[0234] Clause 39. The method of any of clauses 35 to 38, wherein the pressure exerted by the steam varies as the forming tool moves.

[0235] Clause 40. The method of any of clauses 35 to 39, wherein the forming tool is positioned on a positioning device.

[0236] Clause 41. The method of any of clauses 1-20, comprising spraying steam onto the filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and bonded, the spraying of steam heating at least a portion of the filaments; and engaging a shaping tool with the filaments heated by the steam, the engaging of the shaping tool reforming or consolidating the filament mesh structure.

[0237] Clause 42. The method of clause 42, wherein the filaments are heated by steam to a temperature below the melting temperature of the thermoplastic material.

[0238] Clause 43. The method of clause 41 or 42, wherein steam is sprayed onto the filament mesh structure prior to engaging a forming tool with the filament mesh structure.

[0239] Clause 44. The method of any of clauses 41-43, wherein a liquid coating builds up on the filaments as steam is sprayed onto the filament mesh structure.

[0240] Clause 45. The method of Clause 44, wherein the forming tool contacts the liquid coating.

[0241] Clause 46. The method of any of clauses 41-45, wherein the shaping tool is heated before the shaping tool engages the filament.

[0242] Clause 47. The method of any of clauses 41-46, wherein the steam heats the shaping tool while the shaping tool is engaged with the filament.

[0243] Clause 48. The method of any of clauses 41 to 47, wherein spraying the steam includes spraying the steam through a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, and a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam supplied to the first nozzle by the first nozzle valve is different from an amount of steam supplied to the second nozzle by the second nozzle valve.

[0244] Clause 49. The method of any of clauses 41-48, further comprising terminating the spray of steam after reforming the filament mesh structure and separating the forming tool from the filament mesh structure.

[0245] Clause 50. The method of any of clauses 41-49, wherein the steam heats the shaping tool before the shaping tool engages the filament and heats the shaping tool while the shaping tool engages the filament.

[0246] Clause 51. The method of any of clauses 41 to 50, wherein spraying the steam includes spraying the steam with a forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0247] Clause 52. The method of clause 51, wherein the plurality of nozzles do not contact the filament when spraying the steam.

[0248] Clause 53. The method of clause 51 or 52, wherein engaging the shaping tool with the filaments includes applying pressure to actuate a tool body at least partially into the filament mesh structure to reform the filament mesh structure.

[0249] Clause 54. The method of any of clauses 51-53, wherein the plurality of nozzles are positioned spaced apart from the filament mesh structure when the tool body is actuated at least partially into the filament mesh structure.

[0250] Clause 55. The method of any of clauses 1-20, further comprising spraying steam onto a filament mesh structure using a shaping tool, the filament mesh structure being comprised of randomly looped and bonded filaments of thermoplastic material, the shaping tool having a nozzle for spraying steam, the steam heating and applying pressure to at least some of the filaments reforming the filament mesh structure, the shaping tool not engaging the filament mesh structure.

[0251] Clause 56. The method of clause 55, wherein reforming the filament mesh structure includes moving the nozzle relative to the filament mesh structure while spraying steam.

[0252] Clause 57. The method of clause 56, wherein the nozzle is moved while spraying steam to heat and reform additional filaments of the filament mesh structure.

[0253] Clause 58. The method of any of clauses 55 to 57, wherein steam is sprayed directly onto the filament mesh structure.

[0254] Clause 59. The method of any of clauses 55 to 58, wherein the pressure exerted by the steam is varied as the forming tool is moved.

[0255] Clause 60. A method according to any of clauses 55 to 59, wherein the forming tool is positioned on a positioning device.

[0256] Clause 61. A method of manufacturing a cushion, the method comprising: forming a trench in a filament mesh structure extending from a first side of the filament mesh structure toward a second side of the filament mesh structure different from the first side, the trench and the second side cooperating to define a foldable connection segment between the trench and the second side; and folding the filament mesh structure along the foldable connection segment.

[0257] Clause 62. The method of clause 61, wherein the foldable connecting segment is linear.

[0258] Clause 63. The method of clause 61 or 62, wherein the foldable connecting segment extends from a third side of the filament mesh structure to a fourth side of the filament mesh structure that is different from said third side.

[0259] Clause 64. The method of clause 63, wherein the third side extends from the first side to the second side.

[0260] Clause 65. The method of clause 63 or 64, wherein the fourth side extends from the first side to the second side.

[0261] Clause 66. The method of any of Clauses 63 to 65, wherein the first side is positioned opposite the second side and the third side is positioned opposite the fourth side.

[0262] Clause 67. The method of any of clauses 61 to 66, wherein a foldable connecting segment connects a first portion of the filament mesh structure to a second portion of the filament mesh structure, and folding the filament mesh structure along the foldable connecting segment includes folding the second portion onto the first portion.

[0263] Clause 68. The method of clause 67, wherein folding the second portion onto the first portion includes folding the second portion into contact with the first portion.

[0264] Clause 69. The method of clause 67, further comprising securing the second portion to the first portion after folding the second portion, thereby holding the second portion in the folded position.

[0265] Clause 70. The method of clause 69, wherein securing the second portion to the second portion comprises adhering the first portion to the second portion.

[0266] Clause 71. The method of clause 69 or 70, wherein securing the second part to the first part comprises attaching the first part to the second part with a fastener.

[0267] Clause 72. The method of any of clauses 61-71, wherein forming trenches in the filament mesh structure comprises cutting the filament mesh structure.

[0268] Clause 73. The method of clause 72, wherein forming trenches in the filament mesh structure includes cutting the filament mesh structure with a fluid jet.

[0269] Clause 74. The method of Clause 73, wherein cutting the filament mesh structure with a fluid jet at least partially forms a cushion.

[0270] Clause 75. The method of clause 74, further comprising attaching the cushion to a frame of the seat assembly.

[0271] Clause 76. The method of clause 75, further comprising placing a trim cover over the cushion and attaching the trim cover to the cushion, the frame, or the cushion and the frame.

[0272] Clause 77. The method of any of clauses 73-76, further comprising forming a filament mesh structure with filaments of thermoplastic material, the filaments being randomly looped and bonded.

[0273] Clause 78. The method of clause 77, wherein forming the filament mesh structure includes extruding a thermoplastic material through a die to form filaments and then passing the filaments through a funnel.

[0274] Clause 79. The method of clause 78, further comprising cutting the filament mesh structure after the filaments pass through the funnel.

[0275] Clause 80. The method of any of clauses 73-79, further comprising controlling the speed of movement of the cutting head to control the depth of cuts into the filament mesh structure.

[0276] Clause 81. The method of clause 80, further comprising decreasing the speed of movement of the cutting head to increase the depth of cut.

[0277] Clause 82. The method of clause 80 or 81, further comprising bringing the cutting head closer to the filament mesh structure to increase the depth of the cut.

[0278] Clause 83. The method of any of clauses 80-82, further comprising increasing the fluid pressure supplied to the cutting head to increase the depth of the cut.

[0279] Clause 84. The method of any of clauses 80-83, further comprising increasing the fluid flow rate of the fluid jet to increase the depth of cut.

[0280] Clause 85. The method of any of clauses 80-84, wherein cutting the filament mesh structure with the fluid jet includes positioning the cutting head at a distance from the filament mesh structure such that the cutting head does not contact the filament mesh structure.

[0281] Clause 86. The method of any of clauses 80-85, further comprising controlling an automated device supporting the cutting head to move the cutting head along a cutting path relative to the filament mesh structure.

[0282] Clause 87. The method of clause 86, further comprising controlling the automation in at least one degree of freedom to move the cutting head along the cutting path.

[0283] Clause 88. The method of clause 86, further comprising controlling an automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

[0284] Clause 89. The method of any of clauses 73-88, further comprising cutting the entire filament mesh structure via a fluid jet.

[0285] Clause 90. The method of any of clauses 73-88, further comprising partially cutting the filament mesh structure via a fluid jet.

[0286] Clause 91. The method of any of clauses 73-90, further comprising cutting one or more of a planar surface and a curved contour of the filament mesh structure via a fluid jet.

[0287] Clause 92. The method of any of clauses 73-91, further comprising cutting one or more of orthogonal surfaces, fillets, chamfers, and trenches in the filament mesh structure via a fluid jet.

[0288] Clause 93. The method of any of clauses 61-71, wherein forming trenches in the filament mesh structure comprises reshaping filaments of the filament mesh structure without severing the filaments.

[0289] Clause 94. The method of clause 93, wherein forming the trenches includes spraying steam onto a filament mesh structure, the filament mesh structure including filaments of a thermoplastic material, the filaments being randomly looped and bonded, the sprayed steam heating at least a portion of the filaments; and engaging a molding tool with the filaments heated by the steam, the engaging the molding tool forming the trenches.

[0290] Clause 95. The method of clause 94, wherein the filaments are heated by steam to a temperature below the melting point of the thermoplastic material.

[0291] Clause 96. The method of clause 94 or 95, wherein steam is sprayed onto the filament mesh structure before the forming tool engages the filaments.

[0292] Clause 97. The method of any of clauses 94-96, wherein a liquid coating is deposited on the filaments as the steam is sprayed onto the filament mesh structure.

[0293] Clause 98. The method of Clause 97, wherein the forming tool contacts the liquid coating.

[0294] Clause 99. The method of any of clauses 94-98, wherein the shaping tool is heated before the shaping tool engages the filament.

[0295] Clause 100. The method of any of clauses 94-99, wherein steam heats the forming tool while the forming tool engages the filament.

[0296] Clause 101. The method of any of clauses 94 to 100, wherein spraying the steam includes spraying the steam through a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam supplied to the first nozzle by the second nozzle valve is different from an amount of steam supplied to the second nozzle by the second nozzle valve.

[0297] Clause 102. The method of any of clauses 94-101, further comprising terminating the spray of steam after reforming the filament mesh structure and separating the forming tool from the filament mesh structure.

[0298] Clause 103. The method of any of clauses 94-102, wherein the steam heats the shaping tool before the shaping tool engages the filament and heats the shaping tool while the shaping tool engages the filament.

[0299] Clause 104. The method of any of clauses 94-103, wherein spraying the steam includes spraying the steam with a forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0300] Clause 105. The method of clause 104, wherein the plurality of nozzles do not contact the filament when spraying the steam.

[0301] Clause 106. The method of clause 104 or 105, wherein engaging the shaping tool with the filament includes actuating a tool body at least partially within the filament mesh structure to apply pressure to reshape the filament mesh structure.

[0302] Clause 107. The method of any of clauses 104-106, wherein the plurality of nozzles are positioned away from the filament mesh structure when the tool body is actuated at least partially into the filament mesh structure.

[0303] Clause 108. The method of clause 93, wherein forming the trenches includes spraying steam onto the filament mesh structure using a shaping tool, the filament mesh structure being made of randomly looped and bonded filaments of thermoplastic material, the shaping tool having a nozzle for spraying the steam, the steam heating and applying pressure to at least some of the filaments that reform the filament mesh structure to form the trenches, and the shaping tool not engaging the filament mesh structure.

[0304] Clause 109. The method of clause 108, wherein reforming the filament mesh structure includes moving a nozzle relative to the filament mesh structure while spraying steam.

[0305] Clause 110. A method according to clause 109, wherein additional filaments of the filament mesh structure are heated and reformed by moving the nozzle while spraying steam.

[0306] Clause 111. The method of any of clauses 108-110, wherein steam is sprayed directly onto the filament mesh structure.

[0307] Clause 112. A method according to any of clauses 108 to 111, wherein the pressure exerted by the steam varies as the forming tool is moved.

[0308] Clause 113. A method according to any of clauses 108 to 112, wherein the forming tool is placed on a positioning device.

[0309] Clause 114 A cushion comprising a filament mesh structure including filaments of a thermoplastic material, the filaments randomly looped and bonded, the filament mesh structure having a trench extending from a first side of the filament mesh structure toward a second side of the filament mesh structure, the second side being disposed opposite the first side, the trench and the second side cooperating to form a foldable connecting segment therebetween, the foldable connecting segment connecting a first portion of the filament mesh structure to a second portion of the filament mesh structure, the second portion being folded over the first portion.

[0310] Clause 115. The cushion of clause 114, wherein the second side of the first portion contacts the second side of the second portion.

[0311] Clause 116. The cushion of clause 114 or 115, wherein the first portion is secured to the second portion.

[0312] Clause 117. A cushion according to any one of clauses 114 to 116, wherein the cushion is a seat cushion.

[0313] Clause 118. A cushion according to any of clauses 116, wherein the second portion is a side bolster of a seat cushion.

[0314] Clause 119. The cushion of clause 117 or 118, wherein the first portion at least partially defines a central seating portion of the cushion.

[0315] Clause 120. A cushion manufactured by the method of any one of clauses 1 to 20.

[0316] Clause 121. A cushion manufactured by the method of any one of clauses 21 to 34.

[0317] Clause 122. A cushion manufactured by the method of any one of clauses 35 to 40.

[0318] Clause 123. A cushion manufactured by the method of any one of clauses 41 to 54.

[0319] Clause 124. A cushion manufactured by the method of any one of clauses 55 to 60.

[0320] Clause 125. A cushion manufactured by the method of any one of clauses 61 to 113.

[0321] While exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the terms used in the specification are terms of description rather than limitation, and it will be understood that various modifications can be made without departing from the spirit and scope of the invention. Furthermore, features of various embodiments can be combined to form further embodiments of the invention.

Claims

1. A method comprising cutting a filament mesh structure via a fluid jet.

2. The method of claim 1 , wherein the cushion is formed at least in part by cutting a filament mesh structure with a fluid jet.

3. The method of claim 2 further comprising attaching the cushion to a frame of the seat assembly.

4. The method of claim 3 , further comprising placing a trim cover over the cushion and attaching the trim cover to the cushion, the frame, or the cushion and the frame.

5. 5. The method of claim 1, comprising forming a filament mesh structure from filaments of a thermoplastic material, the filaments being randomly looped and bonded.

6. The method of claim 5 , wherein forming the filament mesh structure comprises extruding a thermoplastic material through a die to form filaments, and then passing the filaments through a funnel.

7. The method of claim 6 further comprising cutting the filament mesh structure after the filaments pass through the funnel.

8. 8. The method of claim 1, further comprising controlling the speed of movement of the cutting head to control the depth of the cut into the filament mesh structure.

9. 10. The method of claim 8, further comprising decreasing the speed of movement of the cutting head to increase the depth of the cut.

10. 10. The method of claim 8 or 9, further comprising moving the cutting head closer to the filament mesh structure to increase the depth of the cut.

11. 11. The method of any one of claims 8 to 10, further comprising increasing the fluid pressure supplied to the cutting head to increase the depth of the cut.

12. 12. The method of any one of claims 8 to 11, further comprising increasing the fluid flow rate of the fluid jet to increase the depth of cut.

13. 14. The method of any one of claims 8 to 13, wherein cutting the filament mesh structure with a fluid jet comprises positioning the cutting head at a distance from the filament mesh structure such that the cutting head does not contact the filament mesh structure.

14. 14. The method of any one of claims 8 to 13, further comprising controlling an automated device supporting the cutting head to move the cutting head along a cutting path relative to the filament mesh structure.

15. 15. The method of claim 14, further comprising controlling an automated device in at least one degree of freedom to move the cutting head along the cutting path.

16. 15. The method of claim 14, further comprising controlling an automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

17. 17. The method of any one of claims 1 to 16, further comprising cutting the entire filament mesh structure via a fluid jet.

18. 18. The method of any one of claims 1 to 17, further comprising partially cutting the entire filament mesh structure via a fluid jet.

19. 19. The method of any one of claims 1 to 18, further comprising cutting one or more of flat and curved contours in the filament mesh structure via a fluid jet.

20. 20. The method of any one of claims 1 to 19, further comprising cutting one or more of orthogonal faces, fillets, chamfers, and trenches in the filament mesh structure via a fluid jet.

21. 1. A method of forming a filament mesh structure, the method comprising: spraying steam onto the filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and bonded, the sprayed steam heating at least a portion of the filaments; engaging the filaments heated by the steam with a forming tool; and reforming the filament mesh structure by engaging the forming tool.

22. 22. The method of claim 21, wherein the filaments are heated by steam to a temperature below the melting temperature of the thermoplastic material.

23. 23. The method of claim 21 or 22, wherein steam is sprayed onto the filament mesh structure prior to engaging the forming tool with the filament mesh structure.

24. 24. The method of any one of claims 21 to 23, wherein a liquid coating builds up on the filaments when steam is sprayed onto the filament mesh structure.

25. 25. The method of any one of claims 24, wherein the shaping tool contacts the liquid coating.

26. 26. The method of any one of claims 21 to 25, wherein the shaping tool is heated before engaging the filament.

27. 27. The method of any one of claims 21 to 26, wherein the steam heats the shaping tool while the shaping tool is engaged with the filament.

28. 28. The method of any one of claims 21 to 27, wherein atomizing the steam includes atomizing the steam through a first nozzle and a second nozzle, a first nozzle valve controlling the flow of steam to the first nozzle and a second nozzle valve controlling the flow of steam to the second nozzle, and an amount of steam supplied to the first nozzle by the first nozzle valve differs from an amount of steam supplied to the second nozzle by the second nozzle valve.

29. 29. The method of any one of claims 21 to 28, further comprising terminating the spraying of steam after reforming the filament mesh structure and separating the forming tool from the filament mesh structure.

30. 30. The method of any one of claims 21 to 29, wherein the steam heats the shaping tool before the shaping tool engages the filament and heats the shaping tool while the shaping tool engages the filament.

31. 31. The method of any one of claims 21 to 30, wherein atomizing the steam comprises atomizing the steam with a forming tool, the forming tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

32. 32. The method of claim 31 , wherein the plurality of nozzles do not contact the filament when spraying the steam.

33. 33. The method of claim 31 or 32, wherein engaging the shaping tool with the filament comprises at least partially actuating a tool body into the filament mesh structure to apply pressure to reshape the filament mesh structure.

34. 34. The method of any one of claims 31 to 33, wherein the plurality of nozzles are positioned away from the filament mesh structure when the tool body is actuated at least partially into the filament mesh structure.

35. 1. A method of forming a filament mesh structure, the method comprising: spraying steam onto the filament mesh structure with a forming tool, the filament mesh structure being comprised of randomly looped and bonded filaments of a thermoplastic material, the forming tool having a nozzle for spraying steam, the steam heating and applying pressure to at least some of the filaments reforming the filament mesh structure, the forming tool not engaging the filament mesh structure.

36. 36. The method of claim 35, wherein reforming the filament mesh structure comprises moving a nozzle relative to the filament mesh structure while spraying steam.

37. 37. The method of claim 36, wherein the nozzle is moved while spraying steam to heat and reform additional filaments of the filament mesh structure.

38. 38. The method of any one of claims 35 to 37, wherein steam is sprayed directly onto the filament mesh structure.

39. 39. A method according to any one of claims 35 to 38, wherein the pressure exerted by the steam varies as the moulding tool moves.

40. 40. The method of any one of claims 35 to 39, wherein the forming tool is placed on a positioning device.

41. 21. The method of any one of claims 1 to 20, comprising spraying steam onto the filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and bonded, the spraying of steam heating at least a portion of the filaments, and engaging a shaping tool with the steam-heated filaments, the engaging of the shaping tool reforming the filament mesh structure.

42. 42. The method of claim 41, wherein the filaments are heated by steam to a temperature below the melting temperature of the thermoplastic material.

43. 43. The method of claim 41 or 42, wherein steam is sprayed onto the filament mesh structure prior to engaging the shaping tool with the filament mesh structure.

44. 44. The method of any one of claims 41 to 43, wherein a liquid coating builds up on the filaments when steam is sprayed onto the filament mesh structure.

45. 45. The method of claim 44, wherein the shaped tool contacts the liquid coating.

46. 46. ​​The method of any one of claims 41 to 45, wherein the shaping tool is heated before engaging the filament.

47. 47. The method of any one of claims 41 to 46, wherein the steam heats the shaping tool while the shaping tool is engaged with the filament.

48. 48. The method of any one of claims 41 to 47, wherein atomizing the steam includes atomizing the steam through a first nozzle and a second nozzle, a first nozzle valve controlling the flow of steam to the first nozzle and a second nozzle valve controlling the flow of steam to the second nozzle, and an amount of steam supplied to the first nozzle by the first nozzle valve differs from an amount of steam supplied to the second nozzle by the second nozzle valve.

49. 49. The method of any one of claims 41 to 48, further comprising terminating the spray of steam and separating the forming tool from the filament mesh structure after reforming the filament mesh structure.

50. 50. The method of any one of claims 41 to 49, wherein the steam heats the shaping tool before the shaping tool engages the filament and heats the shaping tool while the shaping tool engages the filament.

51. 51. The method of any one of claims 41 to 50, wherein atomizing the steam comprises atomizing the steam with a forming tool, the forming tool comprising a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

52. 52. The method of claim 51, wherein the plurality of nozzles do not contact the filament when spraying the steam.

53. 53. The method of claim 51 or 52, wherein engaging the shaping tool with the filaments comprises applying pressure by actuating a tool body at least partially into the filament mesh structure to reform the filament mesh structure.

54. 54. The method of any one of claims 51 to 53, wherein the plurality of nozzles are positioned away from the filament mesh structure when the tool body is actuated at least partially into the filament mesh structure.

55. 21. The method of any one of claims 1 to 20, further comprising spraying steam onto a filament mesh structure using a shaping tool, the filament mesh structure being comprised of randomly looped and bonded filaments of thermoplastic material, the shaping tool having a nozzle for spraying steam, the steam heating and applying pressure to at least some of the filaments reforming the filament mesh structure, and the shaping tool not engaging the filament mesh structure.

56. 56. The method of claim 55, wherein reforming the filament mesh structure comprises moving the nozzle relative to the filament mesh structure while spraying steam.

57. 57. The method of claim 56, wherein the nozzle is moved while spraying steam to heat and reform additional filaments of the filament mesh structure.

58. 58. The method of any one of claims 55 to 57, wherein steam is sprayed directly onto the filament mesh structure.

59. 59. A method according to any one of claims 55 to 58, wherein the pressure exerted by the steam varies as the mould tool is moved.

60. 60. A method according to any one of claims 55 to 59, wherein the forming tool is placed on a positioning device.

61. A method of manufacturing a cushion, the method including: forming a trench in a filament mesh structure extending from a first side of the filament mesh structure toward a second side of the filament mesh structure different from the first side, the trench and the second side cooperating to define a foldable connection segment between the trench and the second side; and folding the filament mesh structure along the foldable connection segment.

62. 62. The method of claim 61, wherein the foldable connecting segments are linear.

63. 63. The method of claim 61 or 62, wherein the foldable connecting segment extends from a third side of the filament mesh structure to a fourth side of the filament mesh structure that is different from the third side.

64. 64. The method of claim 63, wherein the third side extends from the first side to the second side.

65. 65. The method of claim 63 or 64, wherein the fourth side extends from the first side to the second side.

66. 66. The method of any one of claims 63 to 65, wherein the first side is positioned opposite the second side and the third side is positioned opposite the fourth side.

67. 67. The method of any one of claims 61 to 66, wherein a foldable connecting segment connects a first portion of the filament mesh structure to a second portion of the filament mesh structure, and folding the filament mesh structure along the foldable connecting segment comprises folding the second portion onto the first portion.

68. 68. The method of claim 67, wherein folding the second portion onto the first portion comprises folding the second portion into contact with the first portion.

69. 68. The method of claim 67, further comprising securing the second portion to the first portion after folding the second portion, thereby holding the second portion in the folded position.

70. 70. The method of claim 69, wherein securing the second portion to the second portion comprises adhering the first portion to the second portion.

71. 71. The method of claim 69 or 70, wherein securing the second portion to the first portion comprises attaching the first portion to the second portion with a fastener.

72. 72. The method of any one of claims 61 to 71, wherein forming trenches in the filament mesh structure comprises cutting the filament mesh structure.

73. 73. The method of claim 72, wherein forming trenches in the filament mesh structure comprises cutting the filament mesh structure with a fluid jet.

74. 74. The method of claim 73, wherein cutting the filament mesh structure with a fluid jet at least partially forms a cushion.

75. 75. The method of claim 74, further comprising attaching the cushion to a frame of the seat assembly.

76. 76. The method of claim 75, further comprising placing a trim cover over the cushion and attaching the trim cover to the cushion, the frame, or the cushion and the frame.

77. 77. The method of any one of claims 73 to 76, further comprising forming a filament mesh structure with filaments of thermoplastic material, the filaments being randomly looped and bonded.

78. 78. The method of claim 77, wherein forming the filament mesh structure comprises extruding a thermoplastic material through a die to form filaments and then passing the filaments through a funnel.

79. 80. The method of claim 78, further comprising cutting the filament mesh structure after the filaments have passed through the funnel.

80. 80. The method of any one of claims 73 to 79, further comprising controlling the speed of movement of the cutting head to control the depth of cuts into the filament mesh structure.

81. 81. The method of claim 80, further comprising decreasing the speed of movement of the cutting head to increase the depth of the cut.

82. 82. The method of claim 80 or 81, further comprising bringing the cutting head closer to the filament mesh structure to increase the depth of the cut.

83. 83. The method of any one of claims 80 to 82, further comprising increasing the fluid pressure supplied to the cutting head to increase the depth of the cut.

84. 84. The method of any one of claims 80 to 83, further comprising increasing the fluid flow rate of the fluid jet to increase the depth of cut.

85. 85. The method of any one of claims 80 to 84, wherein cutting the filament mesh structure with a fluid jet comprises positioning the cutting head at a distance from the filament mesh structure such that the cutting head does not contact the filament mesh structure.

86. 86. The method of any one of claims 80 to 85, further comprising controlling an automated device supporting the cutting head to move the cutting head along a cutting path relative to the filament mesh structure.

87. 87. The method of claim 86, further comprising controlling automation in at least one degree of freedom to move the cutting head along the cutting path.

88. 87. The method of claim 86, further comprising controlling an automated mechanism in at least three degrees of freedom to move the cutting head along the cutting path.

89. 89. The method of any one of claims 73 to 88, further comprising cutting the entire filament mesh structure via a fluid jet.

90. 89. The method of any one of claims 73 to 88, further comprising partially cutting the filament mesh structure via a fluid jet.

91. 91. The method of any one of claims 73 to 90, further comprising cutting one or more of a planar surface and a curved contour of the filament mesh structure via a fluid jet.

92. 92. The method of any one of claims 73 to 91, further comprising cutting one or more of orthogonal surfaces, fillets, chamfers, and trenches in the filament mesh structure via a fluid jet.

93. 72. The method of any one of claims 61 to 71, wherein forming trenches in the filament mesh structure comprises reshaping filaments of the filament mesh structure without severing the filaments.

94. 94. The method of claim 93, wherein forming the trenches comprises spraying steam onto a filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and bonded, the sprayed steam heating at least a portion of the filaments; and engaging a molding tool with the steam-heated filaments, the engaging molding tool forming the trenches.

95. 95. The method of claim 94, wherein the filaments are heated by steam to a temperature below the melting point of the thermoplastic material.

96. 96. The method of claim 94 or 95, wherein steam is sprayed onto the filament mesh structure before the shaping tool engages the filaments.

97. 97. The method of any one of claims 94 to 96, wherein a liquid coating is deposited on the filaments when steam is sprayed onto the filament mesh structure.

98. 98. The method of claim 97, wherein the shaped tool contacts the liquid coating.

99. 99. The method of any one of claims 94 to 98, wherein the shaping tool is heated before engaging the filament.

100. 100. The method of any one of claims 94 to 99, wherein steam heats the shaping tool while the shaping tool engages the filament.

101. 101. The method of any one of claims 94 to 100, wherein the atomization of steam comprises atomization of steam through a first nozzle and a second nozzle, a first nozzle valve controls the flow of steam to the first nozzle, a second nozzle valve controls the flow of steam to the second nozzle, and an amount of steam supplied to the first nozzle by the second nozzle valve is different from an amount of steam supplied to the second nozzle by the second nozzle valve.

102. 102. The method of any one of claims 94 to 101, further comprising terminating the spray of steam after reforming the filament mesh structure and separating the forming tool from the filament mesh structure.

103. 103. The method of any one of claims 94 to 102, wherein the steam heats the shaping tool before the shaping tool engages the filament and heats the shaping tool while the shaping tool engages the filament.

104. 104. The method of any one of claims 94 to 103, wherein spraying the steam comprises spraying the steam with a forming tool, the forming tool comprising a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

105. 105. The method of claim 104, wherein the plurality of nozzles do not contact the filament when spraying the steam.

106. 106. The method of claim 104 or 105, wherein engaging the shaping tool with the filament comprises actuating a tool body at least partially into the filament mesh structure to apply pressure to reshape the filament mesh structure.

107. 107. The method of any one of claims 104 to 106, wherein the plurality of nozzles are positioned away from the filament mesh structure when the tool body is actuated at least partially into the filament mesh structure.

108. 94. The method of claim 93, wherein forming the trenches includes spraying steam onto the filament mesh structure using a shaping tool, the filament mesh structure being made of randomly looped and bonded filaments of thermoplastic material, the shaping tool having a nozzle for spraying the steam, the steam heating and applying pressure to at least some of the filaments that reform the filament mesh structure to form the trenches, and the shaping tool not engaging the filament mesh structure.

109. 109. The method of claim 108, wherein reforming the filament mesh structure comprises moving a nozzle relative to the filament mesh structure while spraying steam.

110. 110. The method of claim 109, wherein additional filaments of the filament mesh structure are heated and reformed by moving the nozzle while spraying steam.

111. 111. The method of any one of claims 108 to 110, wherein steam is sprayed directly onto the filament mesh structure.

112. 112. A method according to any one of claims 108 to 111, wherein the pressure exerted by the steam varies as the moulding tool is moved.

113. 113. A method according to any one of claims 108 to 112, wherein the moulding tool is placed on a positioning device.

114. 1. A cushion comprising: a filament mesh structure including filaments of a thermoplastic material, the filaments being randomly looped and bonded together, the filament mesh structure having a trench extending from a first side of the filament mesh structure toward a second side of the filament mesh structure, the second side being disposed opposite the first side, the trench and the second side cooperating to form a foldable connecting segment therebetween, the foldable connecting segment connecting a first portion of the filament mesh structure to a second portion of the filament mesh structure, the second portion being folded over the first portion.

115. 115. The cushion of claim 114, wherein the second side of the first portion contacts the second side of the second portion.

116. 116. The cushion of claim 114 or 115, wherein the first portion is secured to the second portion.

117. 117. A cushion according to any one of claims 114 to 116, wherein the cushion is a seat cushion.

118. 117. The cushion of any one of claims 116, wherein the second portion is a side bolster of a seat cushion.

119. 119. The cushion of claim 117 or 118, wherein the first portion at least partially defines a central seating portion of the cushion.

120. A cushion manufactured by the method of any one of claims 1 to 20.

121. A cushion manufactured by the method of any one of claims 21 to 34.

122. A cushion manufactured by the method of any one of claims 35 to 40.

123. 55. A cushion manufactured by the method of any one of claims 41 to 54.

124. 61. A cushion made by the method of any one of claims 55 to 60.

125. 114. A cushion manufactured by the method of any one of claims 61 to 113.

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