Method and apparatus for producing vehicle interior parts

Abstract

An apparatus and method for producing a vehicle interior part can include creating a plurality of molten polymer filaments, applying a fluid flow to the molten filaments while in a tank to impart a desired shape, and cooling the molten filaments to form an interconnected filament structure. Assemblies, systems, and methods are provided for forming multiple strands of molten thermoplastic resin into a contoured, one-piece mesh product via at least one forming conveyor. Another assembly, system, and method is provided for forming multiple strands of molten thermoplastic resin into a contoured, one-piece mesh product via an actuator assembly having one or more actuators.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of Danish (DK) Patent Application No. PA202370255, filed May 26, 2023, U.S. Provisional Application No. 63 / 355,809, filed June 27, 2022, U.S. Provisional Application No. 63 / 356,549, filed June 29, 2022, and U.S. Provisional Application No. 63 / 503,292, filed May 19, 2023, the disclosures of which are incorporated herein by reference in their entireties.

[0002] Various embodiments of the present disclosure relate to methods and apparatus for producing vehicle interior components, seat cushions, and assemblies, systems, and methods for manufacturing or forming seat cushions. [Brief explanation of the drawings]

[0003] [Figure 1] 1 is a schematic diagram illustrating systems and methods according to embodiments described herein. [Figure 2] 1 is a schematic diagram illustrating systems and methods according to embodiments described herein. [Figure 3] 1 illustrates a connected filament structure formed in accordance with embodiments described herein for use as a cushion blank for a vehicle seat having side bolsters. [Figure 4] 1 illustrates a connected filament structure formed in accordance with embodiments described herein for use as a cushion blank for a vehicle seat having a concave central portion. [Figure 5] 1 illustrates a connected filament structure formed in accordance with embodiments described herein for use as a cushion blank for a vehicle seat having channels. [Figure 6] FIG. 1 is a front perspective view of a seat assembly according to some embodiments. [Figure 7]FIG. 7 is a partial front perspective view of a cushion of the seat assembly of FIG. 6 according to some embodiments. [Figure 8] 8 is a schematic front view of a system for manufacturing the seat cushion of FIG. 7. [Figure 9] FIG. 9 is a schematic front view of a conveyor assembly of the system of FIG. 8, according to some embodiments. [Figure 10] FIG. 9 is a schematic front perspective view of a conveyor assembly of the system of FIG. 8, according to some embodiments. [Figure 11] FIG. 10 is a front view of a cushion manufactured using the conveyor assembly of FIG. 9. [Figure 12] FIG. 9 is a schematic front view of a conveyor assembly of the system of FIG. 8, according to some embodiments. [Figure 13] FIG. 13 is a front view of a cushion manufactured using the conveyor assembly of FIG. 12. [Figure 14] 9 is a schematic side view of an actuator assembly for use with the system of FIG. 8, according to some embodiments. [Figure 15] FIG. 15 is a schematic top view of the actuator assembly of FIG. 14. [Figure 16] 1 is a schematic diagram of a system having an assembly and one or more subassemblies, according to some embodiments. [Figure 17] 1A-1C illustrate methods of forming and shaping a product using an assembly and one or more subassemblies, according to some embodiments. [Figure 18] 1 illustrates a method of forming and shaping a product according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0004] 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 described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily drawn to 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 to variously employ the embodiments according to the present disclosure.

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

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

[0008] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. The term "and / or," as used herein, will also be understood to refer to and encompass any and all possible combinations of one or more of the associated listed items. Furthermore, the terms "comprising" and / or "including," as used herein, will be understood to specify the presence of stated features, integers, steps, operations, elements, and / or components, but not to exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0009] As used herein, the term "when" is interpreted to mean "when," or "upon," or "in response to determining," or "in response to detecting," optionally depending on the context. Similarly, the phrases "when determined" or "when [specified condition or event] is detected" are interpreted to mean "upon determining," or "in response to determining," or "upon detecting [specified condition or event]," optionally depending on the context.

[0010] The term controller may refer to one or more controllers or control modules for various components and systems. Controllers and control systems may include any number of controllers, may be integrated into a single controller, or may have various modules. Some or all of the controllers may be connected by a controller area network (CAN) or other system. It is recognized that any controller, circuit, or other electrical device disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., flash memory, random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variations), and software that cooperate with each other to perform the operation(s) 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.

[0011] Referring to FIG. 1, a schematic diagram of a system 10 usable with a method 11 according to embodiments described herein is shown. A hopper 12 holds solid granules of polymeric material 14 to be extruded. In some embodiments, material 14 is linear low-density polyethylene (LLDPE), although the methods described herein may use different types of polymers as long as they are desirable and effective for producing the finished product. Material 14 is fed from hopper 12 to an extruder 16. The extruder 16 melts the material 14 and transfers it to a die plate apparatus 18 including a die plate 20. The extruder 16 may be, for example, a conventional extruder with a barrel containing a rotatable screw. The rotation of the screw moves the material 14 through the barrel and serves to heat the material due to friction generated as the screw rotates. A heating element may be disposed on the barrel to heat the polymeric material 14 within the barrel.

[0012] Material 14 exits extruder 16 at location 22 in a pressurized, molten state. Unless otherwise specified, the term "molten" as used herein means that the material is at least partially melted. This does not mean that the material is necessarily in a completely liquid state; rather, it means that the material is not completely solid and can still flow through the elements of system 10. For example, the molten material may still be able to flow through die plate 20, but may be very viscous and beginning to solidify. When solid granules of polymeric material 14 are melted in extruder 16, the material begins to cool as the extruder screw ceases to agitate and moves away from any heaters. At different points in process 11, the material may have a higher or lower viscosity, but is still partially melted and able to flow, even if slowly, and the term "molten" is applied herein.

[0013] The die plate 20 extrudes the material 14 into filaments 24. More specifically, the die plate 20 has a plurality of holes 21 (only some of which are labeled in FIG. 1 for clarity) disposed therethrough through which the molten material 14 passes. A single filament 24 is extruded from each die plate hole. The filament 24 falls downward from the die plate 20 under the pressure and gravity of the system into a funnel 26. The funnel 26 serves to join or gather the filaments 24 into a more compact arrangement in which the filaments 24 bend or loop, with each filament 24 contacting and joining at least one other filament 24. In some embodiments, the funnel 26 has a funnel inlet 28 and a funnel outlet 30 that is smaller than the funnel inlet 28. More specifically, the funnel 26 has a funnel outlet 30 that is narrower than the funnel inlet 28. The individual separated filaments 24 enter the funnel inlet 28, and then as the filaments 24 accumulate and slide down the funnel 26 toward the funnel outlet 30, they bend or loop and move into contact with each other, and the connected filament structure 32 exits the funnel outlet 30 and enters the water tank 34. As the filaments 24 reach the funnel 26, the filaments near the outer portion of the funnel 26 (approximately two to three rows) slide down the sloped surface of the funnel 26, thereby creating a skin on the connected filament structure 32.

[0014] The water tank 34 holds water 36 and receives the connected filament structure 32 from the funnel 26. The water 36 serves at least two functions. First, the water 36 temporarily supports the connected filament structure 32, helping to prevent the filament structure 32 from collapsing or condensing into a less open or porous configuration. As such, the water 36 provides some resistance to further bending and looping the filaments 24, further building the connected filament structure 32. Second, the water 36 externally cools and solidifies the polymer filaments 24. The temperature of the water 36 can be much lower than the temperature of the filaments 24 when they leave the die plate 20, for example, the temperature of the ambient environment surrounding the tank 34. While the fluid used in this embodiment is liquid water 36, other types of fluids may be used in other embodiments.

[0015] The water tank 34 includes various rollers and conveyors that help move the connected filament structure 32 through and out of the water 36. The tractor conveyors 38 are submerged in the water 36 and engage opposing sides of the connected filament structure 32, moving the connected filament structure 32 away from the funnel 26 at approximately the same speed as the connected filament structure 32 exits the funnel 26. The gap between opposing portions of the tractor conveyor 38 is slightly narrower than the width of the connected filament structure 32, allowing the tractor conveyor 38 to better grip the connected filament structure 32. As noted above, FIG. 1 is a schematic diagram and is simplified for illustrative purposes. For example, conveyors such as the tractor conveyor 38 could be positioned toward the front or rear of the system 10 when the system 10 is oriented as shown in FIG. 1, rather than toward the left and right sides as shown.

[0016] Additional rollers 40 help keep the connected filament structure 32 submerged and guide the connected filament structure 32 through the water 36 toward a conveyor belt 42 and shaker table 44 positioned outside the water tank 34. The shaker table 44 agitates the connected filament structure 32 while it is on the conveyor belt 42 to remove at least some of the water 36. Pressurized air may also be directed toward the connected filament structure 32, which may compress the connected filament structure 32 to remove more of the water 36. Finally, the connected filament structure 32 may be cut to a desired size and shape.

[0017] FIG. 2 illustrates a portion of a system 46 similar to the system 10 illustrated in FIG. 1 . This portion of the system 46 can be used to perform a method 48 according to embodiments described herein. The system 46 includes a die plate 50 having a plurality of holes disposed therethrough, which can be positioned at the end of an extruder, such as the extruder 16 illustrated in FIG. 1 . As with the method 11 described in connection with FIG. 1 , as the molten polymer moves through the holes in the die plate 50, a plurality of molten polymer filaments 52 (only some of which are labeled in FIG. 2 for clarity) are formed. The molten polymer filaments 52 move downward from the die plate 50 into a funnel 54, which serves to connect the molten polymer filaments 52 and guide them into a fluid bath 56, which can be used to cool the molten polymer, as described above. In this embodiment, the bath 56 is a tank filled with water 58; however, in other embodiments, a fluid bath, such as the fluid bath 56, can be filled with a fluid other than water, depending on the particular application.

[0018] As the molten polymer filaments 52 enter the fluid 58, they cool and begin to form connected filament structures 59. At this stage, the filaments 52 are just beginning to form a more solid structure, but are still flexible. More specifically, the filaments 52 forming the beginning of the connected filament structures 59 can be moved and positioned to assume a different shape that will remain when the filaments 52 become fully solid. A tractor conveyor 60 engages the connected filament structures 59 and moves them away from the funnel 54. Similar to the system 10 shown in FIG. 1, the system 46 can include additional rollers, conveyors, etc. to guide the filament structures 59 through the remainder of the system 46. As shown in FIG. 2, the system 46 also includes a conduit device 62 having several conduits 64. The conduits 64 can be configured, for example, as tubes for adding a fluid flow to the molten polymer filaments 52 as they begin to cool within the fluid bath 56. On the opposite side of the connected filament structure 59 is another conduit or tube 66 that is also configured to apply a fluid flow to the filaments 52 as they begin to cool within the water bath 56 .

[0019] According to the methods described herein, the tubes 64, 66 can be used to apply a fluid flow to the molten polymer filament 52 so as to impart a desired shape to the filament 52 to form a connected filament structure having a desired shape. In the embodiment shown in FIG. 2, there are three tubes 64 on one side of the filament 52 and one tube 66 on the other side of the filament 52. In other embodiments, a different conduit device having a different number of tubes may be used. For example, a conduit device as used with the embodiments described herein may have a "stacked" arrangement of the tubes 64, as shown in FIG. 2, where the tubes 64 may be arranged horizontally in a row or may be positioned in an array pattern to achieve a desired shape. As described above, the tubes 64, 66 are configured to apply a fluid flow to the filament 52.

[0020] In the embodiment shown in FIG. 2 , the fluid used for the fluid flow is water 58 drawn from a water tank. A pump or other device can be used to direct the fluid through tubes 64, 66 toward the filament 52. In other embodiments, other fluids may be used, including liquids other than those filling the tank 56, or the fluid may be mostly or entirely gaseous, such that air or some other gas flows toward the filament 52. Also, as shown in FIG. 2 , tubes 64 and 66 are positioned to apply fluid flow in two different directions, i.e., tube 64 applies a fluid flow in a direction that is diametrically opposed to the fluid flow applied by tube 66. In other embodiments, a single tube or multiple tubes can apply fluid flow in a single direction or in different directions that are not opposite each other.

[0021] Each of the tubes 64 includes a nozzle 68 positioned at its end closest to the filament 52. Similarly, the tube 66 has a nozzle 70 positioned at its end closest to the filament 52. These nozzles 68, 70 can be convergent, i.e., have outlet openings smaller than the inner diameter of the tubes 64, 66. Alternatively, the nozzles 68, 70 can be divergent, i.e., function as diffusers with outlet openings larger than the inner diameter of the tubes 64, 66. In some embodiments, different combinations of convergent and divergent nozzles can be used to achieve the desired shape of the connected filament structure 59. In the embodiment shown in FIG. 2, the nozzles 68, 70 are positioned approximately 10 millimeters (mm) to 15 mm from the surface of the filament 52, although in other embodiments, the nozzles 68, 70 can be positioned closer to or farther from the filament depending on the desired effect. Although tubes 64, 66 are shown on either side of filament 52, in other embodiments, a single tube or multiple tubes may be positioned at different locations around the outside of filament 52, again based on the desired final shape of connected filament structure 59.

[0022] As the molten polymer filaments 52 cool and begin to form the connected filament structure 59, the molten polymer filaments 52 gradually solidify, as shown in the lower portion 72 of the connected filament structure 59 positioned near the end of the tractor conveyor 60. As shown in FIG. 2 , fluid flowing through the nozzle 68 contacts the polymer filaments 52 and forms depressions or channels 74 in the connected filament structure 59. Similarly, fluid flowing through the nozzle 70 on the opposite side of the conduit device 62 forms depressions or channels 76, 78 on the other side of the connected filament structure 59. Depending on the size, shape, and arrangement of the tubes and associated nozzles, various shapes can be imparted to connected filament structures, such as the connected filament structure 59.

[0023] This flexibility may be particularly advantageous when the connected filament structure is intended for use as a vehicle interior component. For example, the connected filament structure 59 may be used as a cushion blank for a portion of a vehicle seat. To reduce time and costs, particularly in post-processing operations, the systems and methods described herein may be used to form the connected filament structure 59 to create net-shape or near-net-shape molded structures. For example, fluid flow channels may be positioned on both sides of a seat cushion to aid in forming bolsters or other desired features. FIG. 3 illustrates a connected filament structure forming a cushion blank 80 made using an embodiment such as those described above.

[0024] Specifically, using the embodiments described herein, two channels 82, 84 were formed on either side of a cushion blank 80 by applying a fluid flow to molten polymer filaments in a fluid tank, as shown in FIG. 2 . Two bolsters 86, 88 are positioned on either side of the cushion blank 80, adjacent to the respective channels 82, 84. The bolsters 86, 88 can be formed by applying a fluid flow to the cushion blank 80 on the side opposite the channels 82, 84, pushing the bolster portions 86, 88 upward, as shown in FIG. 3 . Alternatively, a central portion 90 of the cushion blank 80 may be subjected to an array of fluid flows such that pushing the central portion 90 downward raises the bolster portions 86, 88 above the surface 92 of the central portion 90. Some combination of these two techniques may also be used. In this manner, a connected filament structure having a desired shape is created using a fluid flow as described in connection with FIG. 2 .

[0025] Embodiments of the systems and methods described herein can also be used to form different types of shapes useful for different applications. For example, FIG. 4 shows a connected filament structure 94, also intended for use as a cushion blank for a vehicle interior component, such as a vehicle seat. The filament structure 94 includes a somewhat concave central portion 96 formed by an array of fluid streams contacting the sides of the molten polymer filaments as they move through a fluid bath. In this embodiment, the side portions of the filament structure 94 are less pronounced than bolsters, while the central portion 96 is somewhat lower than the sides, thereby forming a desirable shape for a seated occupant. FIG. 5 shows another connected filament structure 98. The filament structure 98 is also configured for use as a cushion blank; in this embodiment, channels 100 are formed in the surface of the cushion blank 98. The channels 100 can form suitable locations for sewn seams on a trim cover; typically, the sewn seams are pulled into the channels or other recesses in the cushioning material, providing an aesthetically pleasing finished product.

[0026] 6 illustrates the seat assembly 120 as a vehicle seat assembly 120, according to some embodiments. Although a vehicle seat assembly 120 is shown and described, any seat assembly 120 may be employed. The seat assembly 120 may be utilized in land vehicles, aircraft, watercraft, etc. The seat assembly 120 may also be utilized as an office chair, comfort chair, etc.

[0027] The illustrated seat assembly 120 includes a seat bottom cushion 122 that supports the pelvis and thighs of a seated occupant. The seat assembly 120 also includes a seat back cushion 124 that supports the back and shoulders of a seated occupant. A trim cover 126 is provided over the seat cushions 122, 124 to conceal the cushions 122, 124 and to provide a uniform, smooth contact surface for the occupant.

[0028] 7, one of the seat cushions 122 is shown partially removed from the seat assembly 120. The seat cushion 122 is formed from a plurality of strands 128 of extruded and expanded thermoplastic resin. The seat cushion 122 is also formed with a base layer 130 bonded to and / or integrally formed with the plurality of strands 128.

[0029] Referring now to FIG. 8 , the seat cushions 122, 124 are manufactured from a system 132 and process for extruded thermoplastic mesh. In the illustrated embodiment, an extruder 134 delivers pressurized molten thermoplastic to an extrusion die 136. The extrusion die 136 is disposed with a plurality of exit ports or nozzles 138 that discharge a plurality of strands 128 of molten thermoplastic. The strands 128 are discharged through a funnel plate 140 into a fluid chamber 142. The funnel plate 140 directs the strands 128 into the fluid chamber 142. The fluid chamber 142 holds a fluid, such as water, that provides resistance and cooling to the strands 128. The fluid chamber 142 provides resistance to the flow of the strands 128, causing the strands 128 to buckle, loop, and cross over adjacent strands 128 within the contours defined by the funnel plate 140. The strands 128 may also expand and float within the fluid chamber 142. The strands 128 are cooled by the fluid within the fluid chamber 142 to form the one-piece nonwoven thermoplastic cushion 122. According to this process, the nonwoven thermoplastic cushion 122 is subjected to resistance by the fluid, which cools and solidifies it.

[0030] The system 132 includes a conveyor assembly 144 within a fluid chamber 142. The conveyor assembly 144 transports a plurality of strands 128 through the fluid chamber 142. The conveyor assembly also provides an outer boundary for the strands 128, shaping the strands 128 to have a contour as the cushion 122. A typical conveyor would otherwise create a cushion with a rectangular cross-section. However, the seat cushion 122 is contoured for occupant support and comfort. The conveyor assembly 144 is a shaping conveyor that forms the contour of the cushion 122.

[0031] The conveyor assembly 144 is shown in FIG. 9. The conveyor assembly 144 includes a pair of conveyors 146, 148. The conveyors 146, 148 are employed to form shapes or features on the mesh cushion 122. The conveyors 146, 148 press a shape onto the mesh cushion 122 within the fluid chamber 142 before the mesh cushion 122 cures and solidifies into its final shape. A preform is formed on the mesh cushion 122 in the initial region as the strands 128 enter the fluid. For example, based on one example of the funnel plate 140 and die plate 136, the conveyors 146, 148 may engage the strands 128 within the first inch of fluid. The conveyors 146, 148 maintain contact with the cushion 122 until the mesh 122 cures, e.g., until the mesh cushion 122 is approximately six inches into the fluid.

[0032] Each of the conveyors 146, 148 includes a track 150, 152 for movement around the conveyor 146, 148, transporting the mesh 122 between the tracks 150, 152. In the embodiment of FIG. 9, the track 150 moves clockwise and the track 152 moves counterclockwise. As shown in FIG. 10, each of the tracks 150, 152 includes a plurality of links 154 pivotally interconnected as a chain link track 150, 152. According to one example, each track 150, 152 includes 96 links 154 having flat or contacting surfaces. Alternatively, the tracks 150, 152 may be formed from a belt or the like.

[0033] 9 , a plurality of molding tools 156 are mounted on the track 150 to form shapes, features, and / or contours 158 in the mesh cushion 122. The molding tools 156 are modular and mounted on the track 150. To allow for automation flexibility, the molding tools 156 are interchangeable, such that different cushion 122 designs can be produced between the tracks 150, 152 by interchanging the molding tools 156. Alternatively, the tracks 150, 152 may be configured to form multiple cushion 122 designs to produce a variety of seat cushions 122 on a single system 132.

[0034] Figure 9 shows that conveyors 146, 148 are oriented parallel, spaced apart, and facing each other. Figure 10 shows that a third conveyor 160 may also be employed to bound a third side of cushion 122 during the forming and cooling process. Third conveyor 160 is oriented adjacent to and perpendicular to conveyors 146, 148. A fourth conveyor (not shown) may also be utilized, oriented parallel and spaced apart from third conveyor 160, to bound and form all sides of cushion 122. Of course, any number of conveyors 146, 148, 160 may be utilized.

[0035] As shown in FIG. 11 , the mesh cushion 122 is shown in its final cured shape with a plurality of recessed features 158 formed from a forming tool 156. The recessed features 158 can create shapes, contours, test markers, location markers, contact surface features, trenches, or structures for attaching the cushion 122 to a seat frame, seat trim, actuators, heat transfer devices, etc. By forming the recessed features 158 simultaneously with the formation of the mesh cushion 122, secondary forming operations can be minimized or eliminated. Instead of forming the cushion 122 with a rectangular cross-section as shown in FIG. 7 , the cushion 122 of FIG. 11 is formed with a contour that requires fewer secondary forming or cutting operations. The forming tool 156 can be provided on any of the conveyors 146, 148, 160.

[0036] 12 illustrates a conveyor assembly 162 according to another embodiment. The conveyor assembly 162 includes a pair of spaced-apart, parallel conveyors 164, 166. As in the previous embodiment, the conveyor assembly 162 is oriented with the fluid chamber 142 to receive, shape, and transport the molten thermoplastic strands 128. A linear actuator 168 cooperates with the conveyors 164, 166 to vary the spacing between the conveyors 164, 166 for shaping the mesh 122. The conveyors 164, 166 are actuated to shape, cool, and translate the mesh 122 through the conveyors 164, 166.

[0037] FIG. 13 shows a cushion 170 formed by the conveyor assembly 162 of FIG. 12. The cushion 170 includes a contour 172 formed during the shaping and transport of the mesh 122 by the conveyor assembly 162. Referring again to FIG. 12, the linear actuator 168 is in communication with a controller 174 for controlling the linear actuator 168 to operate one or more of the conveyors 164, 166. Different mesh cushions 170 having different contours 172 are produced by the conveyor assembly 162 without modifying the tooling of the conveyor assembly 162. Different cushions 170 are produced by running different programs in the controller 174.

[0038] The fluid chamber 142 in FIG. 8 is utilized as a heat transfer chamber 142. The fluid chamber 142 is employed to cool the mesh 122 to solidify and bond the strands 128. The fluid chamber 142 can also be utilized to heat the mesh 122. For example, an inlet region of the fluid can be heated while a subsequent region of the fluid can be cooled to aid in the molding and formation of the cushion 122. For example, the fluid can be heated to 130 degrees Fahrenheit in the entry region of the fluid chamber 142. The heating and cooling settings can be varied for various seat cushion 122 designs.

[0039] 14 and 15 show side and top views, respectively, of an actuator assembly 200 according to some embodiments. According to one non-limiting example, the actuator assembly 200 can be used with the system 132 in place of the conveyor assembly 144 of FIG. 8 or in addition to a conveyor that assists in moving the strands 128 through the fluid chamber 142. The actuator assembly 200 can be positioned at least partially within the fluid chamber 142 or can be submerged within the fluid chamber 142. The actuator assembly 200 is moved and controlled to provide an outer boundary for the strands 128, for example, to shape the contoured strands 128 as the cushion 122, providing the cushion 122 with a non-rectangular cross-section. However, the seat cushion 122 is contoured for occupant support and comfort. The actuator assembly shapes and contours the cushion 122 by applying forces to the strands 128 to locally displace or compress the strands to form features 158.

[0040] The actuator assembly 200 includes one or more actuators 202, such as electromechanical actuators, pneumatic actuators, hydraulic actuators, etc. In one non-limiting example, the actuators 202 are provided as linear actuators.

[0041] A controller 204 is provided for use in controlling the position of each of the actuators 202. The controller may be similar to that described above with respect to controller 174.

[0042] The actuators 202 can be arranged in one or more arrays 206. In the illustrated example, there are two arrays 206 of actuators 202, the arrays on opposite sides of the strand 128 in the assembly 200 to apply a force or pressure to one or both sides of the strand 128.

[0043] In other examples, only a single array may be provided, or more than two arrays may be provided. In one example, only a single array 206 is provided on one side of the strand 128, with a stationary backing support provided on the opposite side from the array 206 to form the strand 128.

[0044] In another example, arrays 206 may be provided on all four sides of the assembly 200 to shape all four sides of the strand 128 as the strand moves through the assembly.

[0045] Each actuator array 206 may include a column 207 containing multiple actuators. Each array 206 may further include one or more layers of columns of actuators.

[0046] In the illustrated example, there are three layers 208 in each array 206, as can be seen in Figure 14, although arrays 206 having fewer or more than three layers are also contemplated. Figure 15 shows one layer 208 in each of the arrays 206, i.e., the top layer, since Figure 15 is a top view of the assembly 200. As shown, the layers 208 in a row can be positioned to be stacked in the direction of product travel.

[0047] Although the arrays of actuators 206 show the actuators 202 in each layer as arranged in linear rows 207 and moving in a common direction, it is contemplated that the actuators 202 may be arranged along curved or otherwise shaped rows or paths and may additionally or alternatively move in different directions relative to one another. For example, the actuators 202 in one array 206 may be oriented to move at an angle, such as an acute angle, relative to other actuators 202 in the same array 206, which may allow for additional profiles or shapes of the strands 128 and the resulting cushion 122.

[0048] The assembly 200 provides a computer-controlled forming assembly or forming ring for the strands 128 using actuators 202 in an array 206. By providing multiple layers 208, an overall contoured surface area can be increased to contact and shape the strands. The actuators 202 of the assembly 200 can be at least partially submerged within the fluid chamber 142 to create a desired form and contour of the cushion 122. The assembly 200 can provide for continuous forming or shaping of the strands 128 using an array 206 of actuators 202. By controlling the position of the actuators 202 in each array 206 as the strands 128 move through the assembly 200 with a controller 204, the profile or shape of the resulting cushion 122 can be dynamically controlled.

[0049] Each of the actuators includes a head 210 at the distal end of a moving actuator arm or member. Heads 210 can be provided in a variety of shapes and sizes and can have curved, flat, or otherwise shaped surfaces that interact with strand material 128. In one example, heads 210 are coated or formed with a rubber material, such as natural or synthetic rubber, for example, to provide additional compression to strand material 128.

[0050] In one example, the head 210 of the actuator 202 directly contacts the strands 128 in the assembly 200. In another example, one or more flexible and / or resilient layers 212 may be provided between the head 210 of the actuator and the strands 128 in the assembly, such that the head 210 of the actuator 202 contacts the layer 212, which in turn contacts the strands 128.

[0051] The controller 204 can control the actuators 202 independently or individually and can actuate one or more actuators 202 (e.g., as a group) to shape the outer surface of the bundle of strands 128 in the assembly 200, thereby providing various contours, shapes, and profiles for the cushion 122. In one example, opposing actuators 202 are actuated to compress the strands of material 128. The various heads 210 of the actuators 202 cooperate to compress the outer periphery of the strands of material 128, creating a unified contoured shape. For example, the controller 204 can control the actuators 202 based on the desired shape of the cushion 122, and the control of the actuators 202 can be based on the cushion 122 being segmented or sliced ​​to correspond to the layers 208 of the array 206.

[0052] The controller 204 can further control the actuation distance, or stroke, of each of the actuators 202 to control the contour and shape of the resulting cushion 122. Additionally, the controller 204 can control the actuation time, or the amount of time that the actuators 202 are in the deployed position or in contact with the strands of material 128, to control the contour and shape of the resulting cushion 122. In one example, the stroke can be controlled by controlling the air pressure to that actuator.

[0053] The controller may receive a signal indicative of the speed of the strands 128 through the assembly 200, i.e., the strand feed rate, to control the actuators 202 to provide the desired profile and shape of the cushion. The controller 204 may further provide a signal to the extruder 134 to control the flow rate or travel speed of the strands 128 from the extruder 134.

[0054] After the strands 128 exit the assembly, for example, through the bottom of the assembly 200 as shown in FIG. 14, the strands 128 may be cut to form individual cushions 122.

[0055] Actuator 202 is used to form shapes or features on mesh cushion 122 by pressing the shape onto mesh cushion 122 within fluid chamber 142 before mesh cushion 122 hardens and sets in its final shape.

[0056] The actuators 202 can be controlled and selectively actuated to form the mesh cushion 122 with the contours, recesses, or features 158, as described above, or other shapes. By forming the contours and recessed features 158 simultaneously with the formation of the mesh cushion 122, secondary forming operations can be minimized or eliminated. Instead of forming the cushion 122 with a rectangular cross-section as shown in Figure 7, the cushion 122 of Figure 11 is formed with a contour that requires fewer secondary forming or cutting operations.

[0057] FIG. 16 is a schematic diagram illustrating a system 250 for use in forming a product 253, e.g., a product formed from multiple strands of thermoplastic resin, e.g., as an interconnected filament structure. A dispenser 252 is provided for dispensing the multiple strands of molten thermoplastic resin. Dispenser 252, according to one example, can comprise an extruder and die as described above. The strands or product can be formed by assembly 254. Assembly 254 can comprise one or more subassemblies. In one example, assembly 254 comprises a single subassembly as described above. In another example, assembly 254 comprises two, three, four, or more subassemblies as described above, in any combination of subassemblies. Each subassembly may be provided as (i) a first subassembly 256 having a conveyor for transporting products and a plurality of shaping tools attached to the conveyor for shaping the products as they are transported along the conveyor, (ii) a second subassembly 258 having a pair of spaced conveyors for transporting products therebetween and an actuator that cooperates with the pair of conveyors to vary the spacing between the pair of conveyors and shape the products as they are transported, (iii) a third subassembly 260 having an actuator array including one or more actuators, each deployable to contact the products, and a controller configured to control the position of each actuator to contact and shape the products as they are moved past the actuator array, or (iv) a fourth subassembly 262 having one or more nozzles positioned to direct fluid toward the products to shape them as they are moved past the one or more nozzles. The subassemblies may be arranged sequentially relative to the products and / or positioned to act on the products simultaneously. FIG. 16 shows a representative, non-limiting schematic arrangement of the subassemblies 256, 258, 260, 262; other arrangements of the subassemblies are also contemplated as described herein.As shown, according to one non-limiting example, one or more of the subassemblies may be at least partially submerged in a fluid bath 264 to act on and shape the product. Other elements, such as funnels, and additional roller or tractor conveyors, similar to those described above, may also be provided for use with system 250 and are not shown in the schematic diagram of FIG. 16 for simplicity.

[0058] FIG. 17 illustrates a method 300 for forming a product, such as a contoured, connected filament structure. In various examples, various steps in method 300 can be omitted, added, rearranged, or performed sequentially or simultaneously. In step 302, multiple strands of molten polymer material are extruded, for example, from a die. In step 304, a force is applied to the multiple strands via one or more forming assemblies, thereby forming the multiple strands into a contoured, connected filament structure. The forming assemblies can be provided by one or more nozzles, one or more forming conveyors, and / or one or more actuator assemblies. The forming assemblies are illustrated as having a first forming assembly (304a) that initially forms the product, followed by two forming assemblies (304b, 304c) that simultaneously act on the product to form the product. In other examples, the forming assemblies can be arranged to act on the product in other orders, including sequentially, in parallel, or any combination thereof, to form the product. The forming assembly(ies) form the product by directing one or more fluid jets from one or more nozzles to apply a force to the strands, conveying the strands along one or more forming conveyors to apply a force to the strands, or actuating one or more actuators to contact the strands to apply a force to the strands. The product is cooled in a fluid bath in step 306. Note that steps 304 and 306 may occur simultaneously, as shown, such that the product is formed in the fluid bath while cooling, and the assembly(ies) 304 are at least partially submerged in the fluid bath. Alternatively, the cooling in step 306 may occur simultaneously with or subsequent to only some of the forming steps 304. In step 308, the contoured filament structure is cut to form a member. The member is then used, for example, as a cushion and placed on a seat assembly frame.

[0059] A seat assembly, seat, or chair may be used herein to generally refer to an assembly incorporating the teachings of one or more embodiments disclosed herein, which may include any combination of the embodiments or features of the embodiments disclosed herein. Similarly, the terms seat assembly, seat, or chair may refer to the same or similar assemblies. A seat bottom, back, base, headrest, headrest, or bolster may be used herein to generally refer to any part, region, or portion of a vehicle interior component, seat assembly, vehicle seat, or chair. A filament or strand may be used herein to refer to generally linear polymeric units (although they may loop, intertwine, or fuse with each other to form a mesh-like structure) after being extruded through one or more orifices of a die plate or extrusion die, and these are similarly used to refer to equivalent components. Similarly, the terms product, contoured one-piece mesh product, connected filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion may refer to the same or similar components. The terms funnel and funnel plate may also be used to refer to the same or similar components. In yet another example, tank, water tank, fluid reservoir, and fluid chamber may refer to the same or similar components. In a further example, the terms tractor conveyor and conveyor assembly may refer to the same or similar components. The use of different terms to refer to the same or similar components may be used to avoid confusion when describing different preferred embodiments. These terms may be interchangeable because various components of features from various embodiments may be combined in ways not explicitly described herein.This is without prejudice to the fact that certain terms may provide specific details not included in other interchangeable terms(s) unless otherwise specified (e.g., water tank and fluid chamber refer to similar interchangeable components, but in at least one preferred embodiment the tank is filled with, or arranged to be filled with, water, rather than any liquid when the water tank is in use).

[0060] Method 1800 is described and illustrated with respect to Figure 18. Method 1800 includes dispensing 1802 a plurality of strands (e.g., 24, 52, 128, and / or 253) of a molten polymeric material (e.g., linear low density polyethylene (LLDPE)). In some embodiments, filaments or strands may be used herein to refer to generally linear polymeric units that may be looped, fused, or bonded together to form a mesh-like structure.

[0061] Method 1800 includes applying (1804) a force to the plurality of strands (e.g., 24, 52, 128, and / or 253) via one or more forming assemblies (e.g., 254, 256, 258, 260, 262) to shape the product (e.g., 32, 59, 94, 98, and / or 253) as the product is conveyed. The one or more forming assemblies may be provided by, for example, a nozzle (e.g., 68 and / or 70), a pair of spaced apart conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166), and / or an actuator (e.g., 200, 202). In some embodiments, the nozzles (e.g., 68 and / or 70) can be nozzles in which the fluid flow is in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from a fluid reservoir (e.g., 34, 56, 142, and / or 264) or as another fluid and / or gas. In some embodiments, the conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) can have actuators (e.g., 168) that vary the spacing between the conveyors, the conveyors can be parallel, one or more conveyors can have tracks (e.g., 150, 152) on the conveyors, the tracks can be links or belts, the forming tools (e.g., 156) can be connected to the tracks and can be replaceable, the forming tools can form shapes, contours, and recesses (e.g., 158) in the product, and / or there can be four conveyors surrounding the product.In some embodiments, the actuators (e.g., 202) can be linear actuators, electromechanical actuators, pneumatic actuators, and / or hydraulic actuators, and can further include arrays (e.g., 206) of actuators, e.g., a first array, a second array, a third array, and a fourth array surrounding the product, each array being at least partially submerged in a fluid bath, and an optional elastic layer (e.g., 212) can be positioned between the actuator head (e.g., 210) and the product to control the distance the actuators extend to shape the product, the time the actuators are deployed to contact the product, and / or the actuators based on the rate at which the product is fed. A controller (e.g., 204) can be provided for control, and each actuator (e.g., 202) can have a head (e.g., 210) at a distal end for shaping the product, and the head can be coated or formed of a rubber material, and the head (e.g., 210) can have different shapes, including curved or planar, and / or the actuator array (e.g., 206) can have straight, curved, or angled rows of actuators (e.g., 207), and can include any number of actuators, and each array can also have multiple layers of rows (e.g., 208), e.g., rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators. In some embodiments, one or more molding assemblies thereby shape the multiple strands into a contoured, connected filament structure (e.g., 80, 94, 98, 122, 124, and / or 170, connected filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, and / or cushion).In some embodiments, a cooling chamber, fluid bath, fluid chamber, and / or heat transfer chamber (e.g., 34, 56, 142, and / or 264) can be provided, where the fluid in the fluid bath provides resistance to flow and / or forms the connected filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion. In some embodiments, the connected filament structure (e.g., 32, 59, 94, 98, and / or 253) can be cooled by the fluid in the fluid bath while the fluid in the fluid bath provides resistance to flow and / or can be formed while the strands are in the fluid bath under force.

[0062] In some embodiments, for method 1800, a forming assembly (e.g., 254, 304) comprises at least one of one or more nozzles (e.g., 68 and / or 70), one or more forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166), and / or one or more actuator assemblies (e.g., 200). In some embodiments, the nozzles (e.g., 68 and / or 70) can provide fluid flow in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from a fluid reservoir (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas.In some embodiments, one or more of the forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) can be provided by a pair of spaced apart conveyors, an actuator (e.g., 168) can be provided to vary the spacing between the pair of conveyors to form the product as it is conveyed, the conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) can be parallel, the actuator (e.g., 168) can be a linear actuator, one or more of the conveyors can have tracks thereon, the tracks can be links or belts, and the forming tool (e.g., 156) can be driven by the track. , and interchangeable forming tools can form shapes, contours, and recesses (e.g., 158) in the product, the conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) can be parallel, there can be four conveyors surrounding the product, and / or there can be cooling chambers, fluid baths, fluid chambers, or heat transfer chambers (e.g., 34, 56, 142, and / or 264) where the fluid in the fluid bath provides resistance to flow and forms the interlocked filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, and / or cushion.In some embodiments, the one or more actuators (e.g., 202) can include an array of actuators (e.g., 206), which can include up to a first array, a second array, a third array, and a fourth array surrounding the product, each array can be at least partially submerged in a fluid bath (e.g., 34, 56, 142, and / or 264), an optional resilient layer (e.g., 212) positioned between the actuator head (e.g., 210) and the product, the actuators (e.g., 202) can be linear actuators, electromechanical actuators, pneumatic actuators, hydraulic actuators, and the distance the actuators extend to shape the product, when the actuators are deployed to contact the product, A controller (e.g., 204) can be provided to control the actuators based on the spacing and / or the rate at which the product is fed, each actuator (e.g., 202) can have a head (e.g., 210) at its distal end for shaping the product, the head can be coated or formed from a rubber material, the head can have different shapes including curved or flat, the actuator array (e.g., 206) can have straight, curved, or angled rows of actuators (e.g., 207) and can include any number of actuators, and / or each array can also have multiple layers of rows (e.g., 208), e.g., rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0063] In some embodiments, method 1800 further includes at least one of applying a force to the plurality of strands (e.g., 24, 52, 128, and / or 253) by directing one or more fluid jets from one or more nozzles (e.g., 68 and / or 70), applying a force to the plurality of strands (e.g., 24, 52, 128, and / or 253) by conveying the plurality of strands (e.g., 24, 52, 128, and / or 253) along one or more forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166), and / or applying a force to the plurality of strands (e.g., 24, 52, 128, and / or 253) by actuating one or more actuators (202) to contact the plurality of strands. In some embodiments, the nozzles (e.g., 68 and / or 70) can provide fluid flow in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from a fluid reservoir (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas.In some embodiments, the conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) may be provided by a pair of spaced apart conveyors, and an actuator (e.g., 168) may be provided to vary the spacing between the pair of conveyors to shape the product as it is conveyed, the conveyors may be parallel, the actuator (e.g., 168) may be a linear actuator, one or more of the conveyors may have a track (e.g., 150 and / or 152) thereon, the track may be a link or a belt, and the shaping tool (e.g., 156) may be connected to the track. and may be interchangeable, the forming tools may form shapes, contours, and recesses (e.g., 158) in the product, the conveyors may be parallel and there may be four conveyors surrounding the product, and / or it may include a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) where the fluid in the fluid bath provides resistance to flow and / or may form the interlocked filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, and / or cushion.In some embodiments, the actuator (e.g., 202) can include an array (e.g., 206) of actuators, including up to a first array, a second array, a third array, and a fourth array, surrounding the product, each array can be at least partially submerged in a fluid bath (e.g., 34, 56, 142, and / or 264), an optional elastic layer (e.g., 212) can be positioned between the actuator head (e.g., 210) and the product, and the actuators can be linear, electromechanical, pneumatic, or hydraulic actuators that control the distance the actuator extends to shape the product and the time the actuator is deployed to contact the product. A controller (e.g., 204) can be provided to control the actuators based on the feed rate of the product, and / or the feed rate of the product, and each actuator (e.g., 202) can have a head (e.g., 210) at its distal end for shaping the product, and the head can be coated or formed from a rubber material, and the head can have different shapes including curved or flat, and the actuator array (e.g., 206) can have straight, curved, or angled rows of actuators (e.g., 207) and can include any number of actuators, and / or each array can also have multiple layers of rows (e.g., 208), for example, rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0064] In some embodiments, method 1800 includes moving a plurality of strands (e.g., 24, 52, 128, and / or 253) through a fluid bath (e.g., 34, 56, 142, and / or 264) (e.g., via a tractor conveyor and / or rollers, e.g., 38 and / or 40), and applying a force to the plurality of strands via one or more forming assemblies (e.g., 254, 304) while the plurality of strands is at least partially submerged in the fluid bath (e.g., such that forming occurs within the fluid bath).

[0065] In some embodiments, the method 1800 includes cooling the plurality of strands (52 and / or 59) in a fluid bath (e.g., 34, 56, 142, and / or 264, a cooling chamber, a fluid chamber, and / or a heat transfer chamber).

[0066] In some embodiments, the method 1800 includes cutting the contoured connected filament structure (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymeric units (although they may be looped, fused, or bonded to one another to form a mesh-like structure), and / or the linked filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion may form at least one of a vehicle interior component (e.g., a seat assembly, a seat, or a chair may refer to the same or similar assemblies, and a seat bottom, back, base, headrest, headrest, or bolster may be used herein generally to refer to any component, area, or portion of a vehicle interior component, seat assembly, vehicle seat, or chair), and / or a unitary nonwoven cushion (e.g., 80, 94, 98, 122, 124, and / or 170) (e.g., a cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion).

[0067] In some embodiments, method 1800 includes heating a polymeric material (e.g., linear low density polyethylene (LLDPE)) to a molten state (e.g., heating in an extruder (e.g., 16 and / or 134), a rotating screw extruder, and / or an optional heating element) such that the polymeric material becomes a molten polymer. In some embodiments, method 1800 includes introducing the molten polymer to a die plate (e.g., 18, 20, and / or 136) having a plurality of holes disposed therethrough, such that the molten polymer travels through the holes to form a plurality of strands (e.g., 24, 52, 128, and / or 253) as molten polymer filaments (e.g., from the extruder to the die or die plate). In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear units of polymer (although they may loop, intertwine, or fuse with one another to form a mesh-like structure) after being discharged through one or more orifices of a die plate or extrusion die. In some embodiments, method 1800 includes introducing molten polymer filaments into a vessel (e.g., 34, 56, 142, and / or 264) (e.g., a fluid chamber, a cooling chamber, and / or a heat transfer chamber) to cool the molten polymer filaments. In some embodiments, method 1800 includes applying a fluid stream (e.g., via nozzles 68 and / or 70) to the molten polymer filaments via one or more forming assemblies (e.g., 254, 304) to impart a desired shape to the molten polymer filaments after they are introduced into the bath, thereby forming a connected filament structure having the desired shape (e.g., using nozzles (e.g., 68 and / or 70) in which the fluid stream is directed in a single direction or in at least two different directions, which may or may not be opposite to each other, and the nozzles may be diverging, with an outlet opening larger than the inlet, and / or converging, with an outlet opening smaller than the inlet, and / or a pump may be used to provide fluid to the nozzle from a fluid bath or as a separate fluid / gas).

[0068] In some embodiments, the method 1800 includes a reservoir (e.g., 34, 56, 142, and / or 264) that contains a liquid, and the fluid stream (e.g., through the nozzles 68 and / or 70) includes the liquid. In some embodiments, the nozzles use the fluid in the fluid reservoir.

[0069] In some embodiments, applying the fluid stream to the molten polymer filaments includes moving the fluid stream through a nozzle (e.g., 68 and / or 70) before the fluid stream contacts the molten polymer filaments (e.g., using a pump to pump a fluid from a reservoir or another liquid / gas, including air).

[0070] In some embodiments, for use with method 1800, the nozzles (e.g., 68 and / or 70) are positioned 10 mm to 15 mm from the surface of the molten polymer filament.

[0071] In some embodiments, method 1800 includes adding multiple fluid streams to the molten polymer filament (e.g., via nozzles 68 and / or 70) after the molten polymer filament is introduced into a reservoir (e.g., 34, 56, 142, and / or 264). In some embodiments, nozzles 68 and / or 70 can provide fluid streams in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from the fluid reservoir (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas.

[0072] In some embodiments, using method 1800, a fluid stream (e.g., via nozzles 68 and / or 70) is applied to molten polymer filaments (e.g., 24, 52, 128, and / or 253) in a single direction.

[0073] In some embodiments, using method 1800, a fluid stream (e.g., 68 and / or 70) is applied to a molten polymer filament (e.g., 24, 52, 128, and / or 253) in at least two different directions (e.g., directions that may or may not be opposite to each other).

[0074] In some embodiments, method 1800 includes heating a polymeric material (e.g., linear low-density polyethylene (LLDPE)) to a molten state (e.g., by heating in extruder 16 and / or 134, a rotating screw extruder, and / or using optional heating elements) to create a molten polymeric material. In some embodiments, method 1800 includes extruding the molten polymeric material to form a plurality of molten polymer filaments as a plurality of strands (e.g., 24, 52, 128, and / or 253). In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymeric units (although they may loop, entangle, or fuse together to form a mesh-like structure) after being discharged through one or more orifices of a die plate or extrusion die, e.g., 18, 20, 50, and / or 136. In some embodiments, method 1800 includes cooling the molten polymer material in a fluid bath (e.g., 34, 56, 142, and / or 264, a fluid chamber, a cooling chamber, and / or a heat transfer chamber) to create a connected filament structure (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, method 1800 includes applying a fluid flow (e.g., via nozzles 68 and / or 70) and applying a force via one or more forming assemblies to the molten polymer filaments in the fluid bath so that the connected filament structure has a desired shape as a contoured connected filament structure (e.g., using a nozzle where the fluid flow is in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzle can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzle from the fluid bath (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas).

[0075] In some embodiments, the connected filament structure (e.g., 32, 59, 94, 98, and / or 253) is a cushion blank (e.g., 80, 94, 98, 122, 124, and / or 170) for a vehicle seat, and the desired shape includes two bolsters (e.g., 86 and / or 88) positioned on opposite sides of the cushion blank.

[0076] In some embodiments, method 1800 includes applying a plurality of fluid streams (e.g., via nozzles 68 and / or 70) to molten polymer filaments (e.g., 24, 52, 128, and / or 253) in a fluid bath (e.g., 34, 56, 142, and / or 264) in at least one direction (e.g., in at least two different directions that may or may not be opposite each other).

[0077] In some embodiments, at least one of the fluid streams is applied through a nozzle (eg, 68 and / or 70) (eg, a converging or diverging nozzle).

[0078] In some embodiments, the nozzles (eg, 68 and / or 70) are diverging nozzles (eg, diverging, where the outlet opening is larger than the inlet).

[0079] In some embodiments, for method 1800, each of the fluid streams is applied to the molten polymer filament (e.g., 24, 52, 128, and / or 253) through a respective nozzle (e.g., 68 and / or 70) (e.g., a converging or diverging nozzle).

[0080] In some embodiments, at least one of the nozzles (eg, 68 and / or 70) is a convergent nozzle (eg, convergent, where the outlet opening is smaller than the inlet).

[0081] In some embodiments, the fluid reservoir (e.g., 34, 56, 142, and / or 264) contains a liquid and the fluid stream includes the liquid. In some embodiments, the nozzle uses the fluid in the fluid reservoir (e.g., 34, 56, 142, and / or 264).

[0082] In some embodiments, method 1800 includes heating a polymeric material (e.g., linear low-density polyethylene (LLDPE)) (e.g., by heating in extruder 16 and / or 134, a rotating screw extruder, and / or using optional heating elements) to create a molten polymeric material. In some embodiments, method 1800 includes forming a plurality of molten polymer filaments from the molten polymeric material as a plurality of strands (e.g., 24, 52, 128, and / or 253). In some embodiments, filaments or strands may be used herein to refer to generally linear polymeric units (although they may loop, entangle, or fuse with each other to form a mesh-like structure) after being discharged through one or more orifices of a die plate or extrusion die. In some embodiments, method 1800 includes cooling the molten polymeric material in a fluid bath (e.g., 34, 56, 142, and / or 264, a fluid chamber, and / or a heat transfer chamber). In some embodiments, method 1800 includes directing a fluid stream (e.g., via nozzles 68 and / or 70) into molten polymer material in a fluid bath and applying force via one or more forming assemblies to cause the molten polymer to obtain a desired shape (e.g., using nozzles 68 and / or 70 in which the fluid stream is directed in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles may be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump may be used to provide fluid to the nozzle from the fluid bath or as a separate fluid / gas).

[0083] In some embodiments, method 1800 includes cooling molten polymer in a fluid bath (e.g., 34, 56, 142, and / or 264) to form a connected filament structure (e.g., 32, 59, 94, 98, and / or 253), and imparting a desired shape to the connected filament structure as a contoured connected filament structure by directing a fluid stream (e.g., via nozzles 68 and / or 70) at the molten polymer in the fluid bath. In some embodiments, this technique involves using a fluid stream from a nozzle to form the connected filament structure while in the fluid bath.

[0084] In some embodiments, method 1800 includes directing multiple fluid streams (e.g., from nozzles 68 and / or 70 where the fluid streams are directed in a single direction or at least two different directions that may or may not be opposite each other) into molten polymer material in a fluid bath (e.g., 34, 56, 142, and / or 264) in at least one direction.

[0085] In some embodiments, the connected filament structure is a cushion blank (e.g., 80, 94, 98, 122, 124, and / or 170) for a vehicle seat, and the desired shape includes two bolsters (e.g., 86 and / or 88) positioned on opposite sides of the cushion blank. In some embodiments, filament or strand (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may be looped, fused, or bonded together to form a mesh-like structure), connected filament structure (e.g., 32, 59, 94, 98, and / or 253), filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion.

[0086] In some embodiments, the molten polymeric material is a molten thermoplastic (e.g., linear low density polyethylene (LLDPE)), and the contoured connected filament structure (e.g., 32, 59, 94, 98, and / or 253) is a contoured, one-piece mesh product. In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymeric units (although they may be looped, fused, or bonded together to form a mesh-like structure), connected filament structures (e.g., 32, 59, 94, 98, and / or 253), filament structures, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion. In some embodiments, method 1800 includes conveying a plurality of strands (e.g., 24, 52, 128, and / or 253) along at least one forming conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) of one or more forming assemblies while applying a force to form the plurality of strands into a contoured, one-piece mesh product.In some embodiments, the method 1800 includes a pair of spaced apart conveyors and an actuator (e.g., 168) that varies the spacing between the pair of conveyors to shape the product as it is conveyed, the conveyors can be parallel, the actuator can be a linear actuator, one or more of the conveyors can have tracks (e.g., 150, 152) on the conveyors, the tracks can be links or belts, the shaping tools (e.g., 156) can be connected to the tracks and can be interchangeable, the shaping tools can form shapes, contours, and recesses (e.g., 158) in the product, the conveyors can be parallel, there can be four conveyors surrounding the product, and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) can be provided, where a fluid in the fluid bath provides resistance to flow and can form an interlocked filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, and / or a cushion.

[0087] In some embodiments, the method 1800 includes conveying a plurality of strands (e.g., 24, 52, 128, and / or 253) as a contoured, one-piece mesh product in a plurality of forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166).

[0088] In some embodiments, method 1800 includes translating at least one of a plurality of forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) to vary the spacing between the plurality of forming conveyors while conveying and shaping a plurality of strands (e.g., 24, 52, 128, and / or 253) (e.g., a pair of spaced apart conveyors and an actuator (e.g., 168) can be used to vary the spacing between the pair of conveyors to shape the product as it is conveyed, the conveyors can be parallel, the actuator can be a linear actuator, and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) can be provided).

[0089] In some embodiments, method 1800 includes forming a plurality of strands (e.g., 24, 52, 128, and / or 253) with at least one forming tool (e.g., 156) attached to at least one forming conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) (e.g., one or more conveyors can have tracks (e.g., 150 and / or 152 on conveyors), the tracks can be links or belts, the forming tools can be connected to the tracks and can be interchangeable, the forming tools can form shapes, contours, and recesses (e.g., 158) in the product, the conveyors can be parallel, there can be four conveyors surrounding the product, and / or there can be cooling chambers, fluid baths, fluid chambers, or heat transfer chambers (e.g., 34, 56, 142, and / or 264)).

[0090] In some embodiments, method 1800 includes applying resistance to flow to a plurality of strands (e.g., 24, 52, 128, and / or 253), thereby buckling the plurality of strands, where the buckled strands intersect as a unitary nonwoven (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the fluid in the fluid bath (e.g., 34, 56, 142, and / or 264) applies resistance to flow to form an interlocked filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, or a cushion.

[0091] In some embodiments, the method 1800 includes cooling a plurality of strands (e.g., 24, 52, 128, and / or 253) to combine into a contoured, unitary mesh product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the cooling can occur in a fluid bath, a fluid chamber, and / or a heat transfer chamber (e.g., 34, 56, 142, and / or 264).

[0092] In some embodiments, the method 1800 includes cooling the plurality of strands (e.g., 24, 52, 128, and / or 253) while forming the plurality of strands (e.g., in a fluid bath, fluid chamber, and / or heat transfer chamber (e.g., 34, 56, 142, and / or 264)).

[0093] In some embodiments, the method 1800 includes cooling a plurality of strands (e.g., 24, 52, 128, and / or 253) in a cooling chamber (e.g., a fluid bath, a fluid chamber, and / or a heat transfer chamber (e.g., 34, 56, 142, and / or 264)).

[0094] In some embodiments, the molten polymeric material is a molten thermoplastic (e.g., linear low density polyethylene (LLDPE)), and the contoured, connected filament structure (e.g., 32, 59, 94, 98, and / or 253) is a contoured, one-piece mesh product. In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymeric units (although they may be looped, fused, or bonded together to form a mesh-like structure), connected filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, or cushion. In some embodiments, method 1800 includes actuating one or more actuators (e.g., 202) of one or more molding assemblies to contact the plurality of strands, thereby applying a force and forming the plurality of strands into a contoured, one-piece mesh product.In some embodiments, the array of actuators (e.g., 206) optionally includes up to a first array, a second array, a third array, and a fourth array surrounding the product, each array being at least partially submerged in a fluid bath (e.g., 34, 56, 142, and / or 264), an optional elastic layer (e.g., 212) positioned between the actuator head (e.g., 210) and the product, the actuators being linear, electromechanical, pneumatic, or hydraulic, controlling the distance the actuators extend to shape the product, the time the actuators are deployed to contact the product, and A controller can be provided to control the actuators based on the feed rate of the product and / or the rate at which the product is fed, each actuator can have a head (e.g., 210) at its distal end to shape the product, the head can be coated or formed from a rubber material, the head can have different shapes including curved or flat, the actuator array (e.g., 206) can have straight, curved or angled rows of actuators (e.g., 207) and can include any number of actuators, and / or each array can also have multiple layers of rows (e.g., 208), e.g., rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0095] In some embodiments, method 1800 includes passing a plurality of strands (e.g., 24, 52, 128, and / or 253) through one or more actuators (e.g., 202) and conveying (e.g., via tractor conveyors 38 and / or 60, and / or rollers 40) as a contoured, unitary mesh product (e.g., 32, 59, 94, 98, and / or 253).

[0096] In some embodiments, the method 1800 includes actuating a first actuator of the one or more actuators (e.g., 202) and a second actuator of the one or more actuators (e.g., 202) opposite the first actuator to vary the spacing between the plurality of strands (e.g., 24, 52, 128, and / or 253) while shaping them.

[0097] In some embodiments, method 1800 includes buckling a plurality of strands by applying resistance to flow of the plurality of strands (e.g., 24, 52, 128, and / or 253), wherein the buckled strands intersect as a unitary nonwoven (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, a fluid in a fluid bath (e.g., 34, 56, 142, and / or 264) can apply resistance to flow and / or form a connected filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, or a cushion.

[0098] In some embodiments, method 1800 includes cooling a plurality of strands (e.g., 24, 52, 128, and / or 253) to combine them into a contoured, unitary mesh product (e.g., 32, 59, 94, 98, and / or 253) (e.g., by cooling in a fluid in a fluid bath (e.g., 34, 56, 142, and / or 264)).

[0099] In some embodiments, the method 1800 includes cooling the plurality of strands (e.g., 24, 52, 128, and / or 253) while shaping the plurality of strands (e.g., by applying a force while the strands are in a fluid bath (e.g., 34, 56, 142, and / or 264)).

[0100] In some embodiments, the method 1800 includes cooling a plurality of strands (e.g., 24, 52, 128, and / or 253) in a fluid chamber (e.g., a fluid bath, a cooling chamber, and / or a heat transfer chamber, 34, 56, 142, and / or 264).

[0101] In some embodiments, a vehicle interior part (e.g., a seat assembly, a seat, or a chair may refer to the same or similar assemblies; a seat bottom, a back, a base, a head rest, a headrest, and / or a bolster may be used herein to generally refer to any component, area, or portion of a vehicle interior part, a seat assembly, a vehicle seat, and / or a chair) is formed by any one of the techniques described above, including method 1800.

[0102] In some embodiments, the vehicle interior component is a cushion (eg, 80, 94, 98, 122, 124, and / or 170) for a vehicle seat, with two bolsters positioned on either side of the cushion.

[0103] In some embodiments, the product is manufactured according to the techniques described above, for example via method 1800.

[0104] In some embodiments, the contoured connected filament structure (e.g., 32, 59, 94, 98, and / or 253) forms a product. The method 1800 includes placing the product on a seat frame as a seat cushion.

[0105] In some embodiments, a seat assembly (eg, a seat assembly, a seat, and / or a chair) is manufactured according to the techniques described above, including method 1800.

[0106] Products produced according to the method are described. The method includes extruding a plurality of strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin. In some embodiments, filaments or strands may be used herein to refer to the generally linear polymer units (although they may loop, intertwine, or fuse together to form a mesh-like structure) after being extruded through one or more orifices in a die plate or extrusion die (e.g., 18, 20, and / or 136).

[0107] The method includes forming a plurality of strands into a contoured, one-piece mesh product (e.g., an interlocking filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, and / or a cushion) by applying a force to the plurality of strands via one or more forming assemblies (e.g., 254, 304), the forming assemblies comprising at least one of one or more nozzles (e.g., 68 and / or 70), one or more forming conveyors (e.g., 144, 146, and / or 148), and / or one or more actuator assemblies (e.g., 200, 202). In some embodiments, the nozzles (e.g., 68 and / or 70) can have fluid jets from the nozzles directed in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from a fluid reservoir (e.g., 34, 56, 142, and / or 264) or as another fluid / gas.In some embodiments, the forming conveyor (e.g., 144, 146, and / or 148) can include one or more conveyors with tracks (e.g., 150 and / or 152) on the conveyor, the tracks can be links or belts, the forming tools (e.g., 156) can be connected to the tracks and can be interchangeable, the forming tools can form shapes, contours, and recesses (e.g., 158) in the product, the conveyors can be parallel, there can be four conveyors surrounding the product, and / or a cooling chamber, flow A cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) may be provided, or a pair of spaced apart conveyors and actuators (e.g., 168) may be provided to vary the spacing between the pair of conveyors to shape the product as it is conveyed, the conveyors may be parallel and the actuator (e.g., 168) may be a linear actuator, and / or a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) may be provided.

[0108] In some embodiments, the method includes shaping the plurality of strands (e.g., 24, 52, 128, and / or 253) by actuating one or more actuators (e.g., 202) of one or more forming assemblies to contact the plurality of strands, thereby shaping the plurality of strands into a contoured, unitary mesh product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the actuators (e.g., 202) can include arrays (e.g., 206) of actuators, which can include up to a first array, a second array, a third array, and a fourth array surrounding the product, each array being at least partially submerged in a fluid bath, and an optional resilient layer (e.g., 212) can be positioned between the actuator head (e.g., 210) and the product, and the actuators can be linear, electromechanical, pneumatic, or hydraulic actuators that control the distance the actuators extend to shape the product, the time the actuators are deployed to contact the product, and / or the supply of the product. A controller (e.g., 204) can be provided to control the actuators based on the feed rate, and each actuator can have a head (e.g., 210) at a distal end for shaping the product, the head can be coated or formed from a rubber material, the head can have different shapes including curved or flat, the actuator array (e.g., 206) can have straight, curved, or angled rows of actuators (e.g., 207) and can include any number of actuators, and / or each array can also have multiple layers of rows (e.g., 208), for example, rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0109] In some embodiments, the method includes shaping a plurality of strands (e.g., 24, 52, 128, and / or 253) by conveying the plurality of strands through one or more forming conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) of one or more forming assemblies to contact the plurality of strands, thereby forming the plurality of strands into a contoured, unitary mesh product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, the forming conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) can include one or more conveyors with tracks (e.g., 150 and / or 152) on the conveyor, the tracks can be links or belts, the forming tools (e.g., 156) can be connected to the tracks and can be replaceable, the forming tools form shapes, contours, and recesses (e.g., 158) in the product, the conveyors can be parallel, there can be four conveyors surrounding the product, a cooling chamber, fluid bath, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264), a pair of spaced apart conveyors with an actuator (e.g., 168) that changes the spacing between the pair of conveyors as the product is transported to shape the product, the conveyors can be parallel, and the actuator (e.g., 168) can be a linear actuator.

[0110] In some embodiments, the method includes forming the plurality of strands by directing one or more fluid jets toward the plurality of strands (e.g., 24, 52, 128, and / or 253) through one or more nozzles (e.g., 68 and / or 70) of one or more forming assemblies, contacting the plurality of strands (e.g., 52), thereby forming the plurality of strands into a contoured, unitary mesh product. In some embodiments, the fluid jets from the nozzles can be provided in a single direction or at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from a fluid reservoir (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas.

[0111] In some embodiments, the product (e.g., 24, 52, 128, and / or 253) comprises a one-piece nonwoven cushion (e.g., 80, 94, 98, 122, 124, and / or 170, linked filament structure, filament structure, mesh, extruded material, cushion blank, thermoplastic cushion, mesh cushion, seat cushion, and / or cushion).

[0112] An assembly (e.g., 254) includes at least one of (i) a first subassembly (e.g., 256), (ii) a second subassembly (e.g., 258), (iii) a third subassembly (e.g., 260), and (iv) a fourth subassembly (e.g., 262).

[0113] (i) A first subassembly (e.g., 256) includes a conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) that conveys a product (e.g., an interlocked filament structure, a filament structure, a mesh, an extruded material, a cushion blank, a thermoplastic cushion, a mesh cushion, a seat cushion, or a cushion) and a plurality of forming tools (e.g., 156) attached to the conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) that shape the product (e.g., 32, 59, 94, 98, and / or 253) as the product is transported along the conveyor. In some embodiments, the conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) can be, for example, one or more conveyors with tracks thereon, the tracks can be links or belts, the forming tools (e.g., 156) can be connected to the tracks and can be interchangeable, the forming tools can form shapes, contours, and recesses (e.g., 158) in the product, the conveyors can be parallel, there can be four conveyors surrounding the product, and / or there can be cooling chambers, fluid baths, fluid chambers, or heat transfer chambers.

[0114] (ii) A second subassembly (e.g., 258) includes a pair of spaced apart conveyors (e.g., 164 and / or 166) that convey products (e.g., 32, 59, 94, 98, and / or 253) therebetween, and an actuator (e.g., 168) that cooperates with the pair of conveyors to vary the spacing between the pair of conveyors and shape the products as they are conveyed. In some embodiments, the pair of spaced apart conveyors and the actuator (e.g., 168) can vary the spacing between the pair of conveyors to shape the products as they are conveyed, the conveyors can be parallel, the actuator (e.g., 168) can be a linear actuator, and / or a cooling chamber, fluid reservoir, fluid chamber, or heat transfer chamber (e.g., 34, 56, 142, and / or 264) can be provided.

[0115] (iii) A third subassembly (e.g., 200, 260) comprises an actuator array (e.g., 206) including one or more actuators (e.g., 202), each deployable to contact a product (e.g., 32, 59, 94, 98, and / or 253), and a controller (e.g., 204) configured to control the position of each actuator to contact and shape the product as it is moved past the actuator array. In some embodiments, the third subassembly can be an array (e.g., 206) of actuators (e.g., 202), which can include up to a first array, a second array, a third array, and a fourth array surrounding the product, each array being at least partially submerged in a fluid bath (e.g., 34, 56, 142, and / or 264), and an optional resilient layer (e.g., 212) can be positioned between the actuator head (e.g., 210) and the product, and the actuators (e.g., 202) can be linear actuators, electromechanical actuators, pneumatic actuators, hydraulic actuators, and can control the distance the actuator extends to form the product, the time the actuator is deployed to contact the product, and / or the rate at which the product is fed. A controller (e.g., 204) can be provided to control the actuators in the device, and each actuator (e.g., 202) can have a head (e.g., 210) at its distal end for shaping the product, and the head can be coated or formed from a rubber material, and the head (e.g., 210) can have different shapes, including curved or flat, and the actuator array (e.g., 206) can have rows (e.g., 207) of straight, curved, or angled actuators (e.g., 202) and can include any number of actuators, and / or each array (e.g., 206) can also have multiple layers (e.g., 208) of rows (e.g., 207), e.g., rows stacked on top of each other in the direction of travel so that the product passes through multiple layers of actuators.

[0116] (iv) A fourth subassembly (e.g., 262) includes one or more nozzles (e.g., 68 and / or 70) positioned to direct fluid toward an article (e.g., 32, 59, 94, 98, and / or 253) to shape the article as it moves past the one or more nozzles. In some embodiments, the nozzles can be used to shape the article (e.g., 32, 59, 94, 98, and / or 253) in a fluid bath (e.g., 34, 56, 142, and / or 264), the nozzles can direct fluid flow in a single direction or in at least two different directions that may or may not be opposite to each other, the nozzles can be diverging with an outlet opening larger than the inlet and / or converging with an outlet opening smaller than the inlet, and / or a pump can be used to provide fluid to the nozzles from the fluid bath (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas.

[0117] In some embodiments, the assembly (e.g., 254) further comprises a first subassembly (e.g., 256), one or more conveyors (e.g., 144, 146, 148, 160, 162, 164, and / or 166) having tracks (e.g., 150, 152) on the conveyor, the tracks can be links or belts, the forming tools (e.g., 156) can be connected to the tracks and can be interchangeable, the forming tools can form shapes, contours, and recesses (e.g., 158) in the product, the conveyors can be parallel, there can be four conveyors surrounding the product, and / or cooling chambers, fluid baths, fluid chambers, or heat transfer chambers (e.g., 34, 56, 142, and / or 264) can also be provided.

[0118] In some embodiments, the assembly (e.g., 254) further includes a second conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) that conveys the product (e.g., 32, 59, 94, 98, and / or 253), the second conveyor being spaced apart from the first conveyor and conveying the product between the first and second conveyors (e.g., two conveyors, each of which may have a forming tool 156 on track 152).

[0119] In some embodiments, the assembly (e.g., 254) further comprises a second plurality of forming tools (e.g., 156) attached to the second conveyor (e.g., 144, 146, 148, 160, 162, 164, and / or 166) to form the products (e.g., 32, 59, 94, 98, and / or 253) as the products are transported along the first and second conveyors.

[0120] In some embodiments, the assembly (e.g., 254) further comprises a cooling chamber (e.g., 34, 56, 142, and / or 264) (e.g., fluid bath, fluid chamber, heat transfer chamber) that cools the product (e.g., 24, 52, 128, and / or 253) while it is being transported and formed.

[0121] A system (e.g., 250) is described that includes a dispenser (e.g., 252) of multiple strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin and an assembly 254, as described above, oriented relative to dispenser 252 to receive, convey, and shape the multiple strands.

[0122] In some embodiments, the assembly (e.g., 254) further comprises a second subassembly (e.g., 258, 164, and / or 166) (e.g., a pair of spaced apart conveyors and an actuator (e.g., 168) for varying the spacing between the pair of conveyors and shaping the product (e.g., 24, 52, 128, and / or 253) as the product is conveyed, where the conveyors can be parallel and / or the actuator can be a linear actuator).

[0123] In some embodiments, the assembly (e.g., 254) further comprises a cooling chamber (e.g., 34, 56, 142, and / or 264) (e.g., a fluid bath, fluid chamber, and / or heat transfer chamber) that cools the product (e.g., 32, 59, 94, 98, and / or 253) while it is being transported and formed.

[0124] A system (e.g., 250) is described that includes a dispenser (e.g., 252) of multiple strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin and an assembly (e.g., 254) oriented relative to the dispenser (e.g., 252) to receive, convey, and shape the multiple strands.

[0125] In some embodiments, the assembly (e.g., 254) further comprises a third subassembly (e.g., 200, 260, and / or an array 206 of actuators 202, which may include up to a first array, a second array, a third array, and a fourth array surrounding the product (e.g., 32, 59, 94, 98, and / or 253), where each array 106 is at least partially submerged in a fluid bath (e.g., 34, 56, 142, and / or 264), and an optional resilient layer 212 may be positioned between the actuator head 210 and the product). In some embodiments, the actuators 202 may be linear actuators, electromechanical actuators, pneumatic actuators, or hydraulic actuators. In some embodiments, a controller 204 can be provided to control the distance the actuators 202 extend to shape the product (e.g., 32, 59, 94, 98, and / or 253), the time the actuators 202 are deployed to contact the product (e.g., 32, 59, 94, 98, and / or 253), and / or control the actuators 202 based on the feed rate of the product (e.g., 32, 59, 94, 98, and / or 253). In some embodiments, each actuator 202 can include a head (e.g., 210) at its distal end to shape the product (e.g., 32, 59, 94, 98, and / or 253), the head 210 can be coated or formed from a rubber material, and the head (e.g., 210) can have different shapes, including curved or flat. In some embodiments, the actuator arrays (e.g., 206) can have straight, curved, or angled rows of actuators (e.g., 207), can include any number of actuators, and / or each array (e.g., 206) can also have multiple layers (e.g., 208) of rows (e.g., 207), e.g., rows stacked on top of each other in the direction of travel, such that the products (e.g., 32, 59, 94, 98, and / or 253) pass through multiple layers of actuators (e.g., 202).

[0126] In some embodiments, the assembly (e.g., 254) further comprises a second actuator array (e.g., 206) including one or more second actuators (e.g., 202), each deployable to contact a product (e.g., 32, 59, 94, 98, and / or 253), the second actuator array (e.g., 206) spaced apart from the first actuator array (e.g., 206) so that the product is conveyed therebetween. In some embodiments, the controller (e.g., 204) can be further configured to control the position of each second actuator (e.g., 202) to contact and shape the product (e.g., 32, 59, 94, 98, and / or 253) as the product is moved past the second actuator array (e.g., the array on the second side may be opposite the first array).

[0127] In some embodiments, the assembly (e.g., 254) further comprises a third actuator array (e.g., 206) including one or more third actuators (e.g., 202), each deployable to contact a product (e.g., 32, 59, 94, 98, and / or 253), the third actuator array spaced apart from the first and second actuator arrays (e.g., 206) so that the product is conveyed therebetween. In some embodiments, the controller 204 can be further configured to control the position of each third actuator 202 to contact and shape the product (e.g., 32, 59, 94, 98, and / or 253) as the product is moved past the third actuator array (e.g., a third lateral array).

[0128] In some embodiments, the assembly (e.g., 254) further comprises a fourth actuator array (e.g., 206) including one or more fourth actuators (e.g., 202), each deployable to contact a product (e.g., 32, 59, 94, 98, and / or 253), the fourth actuator array spaced apart from the first, second, and third actuator arrays (e.g., 206) so that the product is conveyed therebetween. In some embodiments, the controller (e.g., 204) can be further configured to control the position of each fourth actuator (e.g., 202) to contact and shape the product (e.g., 32, 59, 94, 98, and / or 253) as the product is moved past the fourth actuator array (e.g., the fourth lateral array).

[0129] In some embodiments, the first actuator array, the second actuator array, the third actuator array, and the fourth actuator array (e.g., 206) (e.g., with actuator arrays on all four sides of the product as it descends into the tank) are positioned to surround the product (e.g., 32, 59, 94, 98, and / or 253).

[0130] In some embodiments, the assembly (e.g., 254) further comprises a fluid chamber (e.g., a fluid bath in which the actuator is at least partially submerged so as to contact the product in the bath) for cooling the product (e.g., 32, 59, 94, 98, and / or 253) while the product is being molded.

[0131] In some embodiments, the assembly (e.g., 254) further comprises a flexible layer (e.g., 212) positioned between at least one of the actuators (e.g., 202) and the product (e.g., 32, 59, 94, 98, and / or 253) (e.g., a resilient layer positioned between the actuator head and the product).

[0132] In some embodiments, the controller (e.g., 204) is further configured to control the stroke distance of at least one of the actuators (e.g., 202) as it forms the product (e.g., by controlling the distance the actuator extends to form the product).

[0133] In some embodiments, the controller (e.g., 204) is further configured to control the actuation time of at least one of the actuators (e.g., 202) in forming the product (e.g., 32, 59, 94, 98, and / or 253) (e.g., by controlling the time the actuator is deployed to contact the product).

[0134] In some embodiments, the controller (e.g., 204) is further configured to receive a signal indicative of a feed rate of the product (e.g., 32, 59, 94, 98, and / or 253) and control at least one of the actuators (e.g., 202) based on the signal.

[0135] In some embodiments, each actuator (eg, 202) comprises a linear actuator.

[0136] In some embodiments, each actuator (e.g., 202) includes a head (e.g., 210) (e.g., the head is at the distal end of the actuator to contact the product (e.g., 32, 59, 94, 98, and / or 253), may be coated or formed from a rubber material, and may be of different shapes, including curved or flat).

[0137] In some embodiments, each head (eg, 210) of the actuator (eg, 202) comprises rubber.

[0138] In some embodiments, each actuator array (e.g., 206) includes a row (e.g., 207) of multiple actuators (e.g., 202) (e.g., the row may be straight or curved and may include any number of actuators).

[0139] In some embodiments, each actuator array (eg, 206) includes one or more layers (eg, 208) of columns (eg, 207).

[0140] In some embodiments, the layers (e.g., 208) of the rows (e.g., 207) are positioned to be stacked in the direction of travel of the products (e.g., 32, 59, 94, 98, and / or 253) (e.g., the products pass through multiple layers of actuators as they travel).

[0141] A system (e.g., 250) is described that includes a dispenser (e.g., 252) of multiple strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin and an assembly (e.g., 254) oriented relative to the dispenser to receive and shape the multiple strands (e.g., 24, 52, 128, and / or 253) as they pass through the assembly.

[0142] In some embodiments, the assembly (e.g., 254) includes a fourth subassembly (e.g., 262, nozzles (e.g., 68 and / or 70) in which the fluid flow is directed in a single direction and / or in at least two different directions that may or may not be opposite each other). In some embodiments, the nozzles (e.g., 68 and / or 70) can be diverging, with an outlet opening larger than the inlet, and / or converging, with an outlet opening smaller than the inlet. In some embodiments, a pump can be used to provide fluid to the nozzles (e.g., 68 and / or 70) from a fluid reservoir (e.g., 34, 56, 142, and / or 264) or as a separate fluid / gas.

[0143] In some embodiments, the nozzles (eg, 68 and / or 70) are oriented to direct the fluid stream in a single direction toward the product (eg, 32, 59, 94, 98, and / or 253).

[0144] In some embodiments, the nozzles (e.g., 68 and / or 70) are oriented to direct the fluid stream toward the product (e.g., 32, 59, 94, 98, and / or 253) in at least two different directions (e.g., directions that may or may not be opposite to each other).

[0145] In some embodiments, at least one nozzle (eg, 68 and / or 70) of the one or more nozzles is a diverging nozzle (eg, diverging, with an outlet opening larger than the inlet).

[0146] In some embodiments, at least one nozzle (eg, 68 and / or 70) of the one or more nozzles is a convergent nozzle (eg, convergent, where the outlet opening is smaller than the inlet).

[0147] In some embodiments, at least one nozzle (e.g., 68 and / or 70) of the one or more nozzles is a diverging nozzle and at least another nozzle (e.g., 68 and / or 70) of the one or more nozzles is a converging nozzle.

[0148] In some embodiments, the assembly (e.g., 254) further comprises a pump fluidly connected to one or more nozzles (e.g., 68 and / or 70) (e.g., the pump may be used to pump fluid from a reservoir (e.g., 34, 56, 142, and / or 264) or another liquid / gas, including air).

[0149] In some embodiments, a system (e.g., 250) is described that includes a dispenser (e.g., 252) of multiple strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin and an assembly (e.g., 254) as described above that is oriented relative to the dispenser to receive and form the multiple strands (e.g., 24, 52, 128, and / or 253) as they pass through the assembly.

[0150] In some embodiments, a system (e.g., 250) is described that includes a dispenser (e.g., 252) of multiple strands (e.g., 24, 52, 128, and / or 253) of molten thermoplastic resin, a fluid bath (e.g., 34, 56, 142, and / or 264), and an assembly (e.g., 254) as described above, where the assembly (e.g., 254) is at least partially submerged within the fluid bath. In some embodiments, filaments or strands (e.g., 24, 52, 128, and / or 253) may be used herein to refer to generally linear polymer units (although they may loop, intertwine, or fuse together to form a mesh-like structure) after being discharged through one or more orifices of a die plate or extrusion die of an extruder (e.g., 16 and / or 134).

[0151] Item 1. A method, in combination with or without any one or more of the following items, comprising dispensing a plurality of strands of molten polymeric material and shaping the plurality of strands into a contoured, connected filament structure by applying a force to the plurality of strands through one or more forming assemblies.

[0152] Item 1A. A method, in combination with or without any one or more of the following items, comprising dispensing a plurality of strands of molten polymer material and applying a force to the plurality of strands via one or more forming assemblies.

[0153] Item 2. The method of any preceding or following item, wherein the forming assembly comprises at least one of one or more nozzles, one or more forming conveyors, or one or more actuator assemblies.

[0154] Item 3. The method of any preceding or following item, further comprising at least one of applying the force to the plurality of strands by directing one or more fluid jets from the one or more nozzles, applying the force to the plurality of strands by conveying the plurality of strands along the one or more forming conveyors, or applying the force to the plurality of strands by actuating one or more actuators to contact the plurality of strands.

[0155] Item 4. The method of any preceding or following item, further comprising: moving the plurality of strands through a fluid bath; and applying the force to the plurality of strands via the one or more forming assemblies while the plurality of strands is at least partially submerged in the fluid bath.

[0156] Item 5. The method of any preceding or following item, further comprising cooling the plurality of strands in the fluid bath.

[0157] Item 6. The method of any preceding or following item, further comprising cutting the contoured connected filament structure to form at least one of a vehicle interior part or a one-piece nonwoven cushion.

[0158] Item 7. The method of any preceding or following item, further comprising: heating the polymer material to a molten state so that the polymer material becomes the molten polymer; introducing the molten polymer into a die plate having a plurality of holes disposed therethrough, whereby the molten polymer moves through the holes to form the plurality of strands as molten polymer filaments; introducing the molten polymer filaments into a tank to cool the molten polymer filaments; and applying a fluid stream to the molten polymer filaments via the one or more forming assemblies to apply the force after the molten polymer filaments are introduced into the tank, thereby imparting a desired shape to the molten polymer filaments and forming the connected filament structure having the desired shape.

[0159] Item 8. The method of any of the preceding or following items, wherein the reservoir contains a liquid and the fluid stream comprises the liquid.

[0160] Item 9. The method of any preceding or following item, wherein applying the fluid stream to the molten polymer filaments includes moving the fluid stream through a nozzle before the fluid stream contacts the molten polymer filaments.

[0161] Item 10. The method of any of the preceding or following items, wherein the nozzle is positioned 10 mm to 15 mm from the surface of the molten polymer filament.

[0162] Item 11. The method of any preceding or following item, further comprising applying a plurality of said fluid streams to said molten polymer filaments after said molten polymer filaments are introduced into said tank.

[0163] Item 12. The method of any of the preceding or following items, wherein the fluid stream is applied to the molten polymer filaments in a single direction.

[0164] Item 13. The method of any of the preceding or following items, wherein the fluid streams are applied to the molten polymer filaments in at least two different directions.

[0165] Item 14. The method of any preceding or following item, further comprising: heating a polymeric material to a molten state to create the molten polymeric material; extruding the molten polymeric material to form a plurality of molten polymer filaments as the plurality of strands; cooling the molten polymeric material in a fluid bath to create a connected filament structure; and applying a fluid flow to apply the force to the molten polymer filaments in the fluid bath via the one or more forming assemblies, so that the connected filament structure has a desired shape for the contoured connected filament structure.

[0166] Item 15. The method of any preceding or following item, wherein the connected filament structure is a cushion blank for a vehicle seat, and the desired shape includes two bolsters positioned on opposite sides of the cushion blank.

[0167] Item 16. The method of any preceding or following item, further comprising applying a plurality of the fluid streams to the molten polymer filaments in the fluid bath in at least one direction.

[0168] Item 17. The method of any of the preceding or following items, wherein at least one of the fluid streams is applied through a nozzle.

[0169] Item 18. The method of any of the preceding or following items, wherein the nozzle is a diverging nozzle.

[0170] Item 19. The method of any of the preceding or following items, wherein each of the fluid streams is applied to the molten polymer filaments through a respective nozzle.

[0171] Item 20. The method of any of the preceding or following items, wherein at least one of the nozzles is a convergent nozzle.

[0172] Item 21. The method of any of the preceding or following items, wherein the fluid reservoir contains a liquid and the fluid stream includes the liquid.

[0173] Item 22. The method of any preceding or following item, further comprising: heating a polymer material to create a molten polymer material; forming a plurality of molten polymer filaments from the molten polymer material into the plurality of strands; cooling the molten polymer material in a fluid bath; and directing a fluid stream at the molten polymer material in the fluid bath and applying the force via the one or more molding assemblies to cause the molten polymer to obtain a desired shape.

[0174] Item 23. The method of any preceding or following item, wherein the molten polymer is cooled in the fluid bath to form a connected filament structure, and the desired shape is imparted to the connected filament structure as the contoured connected filament structure by directing the fluid stream at the molten polymer in the fluid bath.

[0175] Item 24. The method of any preceding or following item, further comprising directing a plurality of said fluid streams into said molten polymeric material in said fluid bath in at least one direction.

[0176] Item 25. The method of any preceding or following item, wherein the connected filament structure is a cushion blank for a vehicle seat, and the desired shape includes two bolsters positioned on opposite sides of the cushion blank.

[0177] Item 26. The method of any preceding or following item, wherein the molten polymeric material is a molten thermoplastic resin and the contoured, connected filament structure is a contoured, one-piece mesh product, the method further comprising conveying the plurality of strands along at least one forming conveyor of the one or more forming assemblies while applying the force, to form the plurality of strands into the contoured, one-piece mesh product.

[0178] Item 27. The method of any preceding or following item, further comprising conveying the plurality of strands as the contoured, one-piece mesh product in a plurality of forming conveyors.

[0179] Item 28. The method of any preceding or following item, further comprising translating at least one of the forming conveyors to vary the spacing between the forming conveyors while conveying and forming the plurality of strands.

[0180] Item 29. The method of any preceding or following item, further comprising shaping the plurality of strands with at least one shaping tool attached to the at least one shaping conveyor.

[0181] Item 30. The method of any preceding or following item, further comprising applying resistance to the flow of the plurality of strands, thereby buckling the plurality of strands, wherein the buckled strands intersect as a unitary nonwoven body.

[0182] Item 31. The method of any preceding or following item, further comprising cooling the plurality of strands to bond them into the contoured, unitary mesh product.

[0183] Item 32. The method of any preceding or following item, further comprising cooling the plurality of strands while forming the plurality of strands.

[0184] Item 33. The method of any preceding or following item, further comprising cooling the plurality of strands in a cooling chamber.

[0185] Item 34. The method of any preceding or following item, wherein the molten polymeric material is a molten thermoplastic resin and the contoured connected filament structure is a contoured one-piece mesh product, the method further comprising actuating one or more actuators of the one or more molding assemblies to contact the plurality of strands, thereby applying the force and molding the plurality of strands into the contoured one-piece mesh product.

[0186] Item 35. The method of any preceding or following item, further comprising conveying the plurality of strands as the contoured, one-piece mesh product through the one or more actuators.

[0187] Item 36. The method of any preceding or following item, further comprising actuating a first actuator of the one or more actuators and a second actuator of the one or more actuators opposite the first actuator to vary the spacing between the plurality of strands while shaping them.

[0188] Item 37. The method of any preceding or following item, further comprising applying resistance to the flow of the plurality of strands, thereby buckling the plurality of strands, wherein the buckled strands intersect as a unitary nonwoven body.

[0189] Item 38. The method of any preceding or following item, further comprising cooling the plurality of strands to bond them into the contoured, one-piece mesh product.

[0190] Item 39. The method of any preceding or following item, further comprising cooling the plurality of strands while forming the plurality of strands.

[0191] Item 40. The method of any preceding or following item, further comprising cooling the plurality of strands in a fluid chamber.

[0192] Item 41. A vehicle interior part formed by the method of any of the preceding or following items.

[0193] Item 42. The vehicle interior part according to item 41, wherein the vehicle interior part is a cushion for a vehicle seat and includes two bolsters positioned on either side of the cushion.

[0194] Item 43. A product manufactured according to the method of any of the preceding or succeeding items.

[0195] Item 44. The contoured connected filament structure forms a product; The method of any of the preceding or following items, wherein the method further comprises installing the product as a seat cushion on a seat frame.

[0196] Item 45. A seat assembly manufactured according to the method of any of the preceding or following items.

[0197] Item 46. A product made according to a method, with or without combination with any one or more of the following items, comprising dispensing a plurality of strands of molten thermoplastic resin and forming the plurality of strands into a contoured, one-piece mesh product by applying a force to the plurality of strands via one or more forming assemblies, the forming assemblies comprising at least one of one or more nozzles, one or more forming conveyors, and / or one or more actuator assemblies.

[0198] Item 47. The product of any preceding or following item, wherein the method further includes shaping the plurality of strands by actuating the one or more actuators of the one or more forming assemblies to contact the plurality of strands, thereby forming the plurality of strands as a contoured, one-piece mesh product.

[0199] Item 48. The product of any preceding or following item, wherein the method further includes shaping the plurality of strands by conveying the plurality of strands through the one or more forming conveyors of the one or more forming assemblies to contact the plurality of strands, thereby forming the plurality of strands as a contoured, one-piece mesh product.

[0200] Item 49. The product of any preceding or following item, wherein the method further includes shaping the plurality of strands by directing one or more fluid jets toward and contacting the plurality of strands through the one or more nozzles of the one or more forming assemblies, thereby forming the plurality of strands into a contoured, one-piece mesh product.

[0201] Item 50. The article of manufacture of any preceding or following item, further comprising an integral nonwoven cushion.

[0202] Item 51. An assembly, comprising: (i) a first subassembly comprising a conveyor for conveying a product and a plurality of forming tools attached to the conveyor for shaping the product as it is conveyed along the conveyor; (ii) a second subassembly comprising a pair of spaced apart conveyors for conveying the product therebetween and an actuator cooperating with the pair of conveyors to vary the spacing between the pair of conveyors to shape the product as it is conveyed; and (iii) a third subassembly comprising one or more actuators, each actuator contacting the product. and a controller configured to control the position of each actuator to contact and shape the product as the product is moved past the actuator array; and / or (iv) a fourth subassembly comprising one or more nozzles positioned to direct fluid towards the product as the product is moved past the one or more nozzles, with or without any one or more of the following items:

[0203] Item 52. The assembly of any preceding or following item, further comprising the first subassembly.

[0204] Item 53. The assembly of any preceding or following item, further comprising a second conveyor for conveying the product, the second conveyor being spaced apart from the first conveyor and conveying the product between the first conveyor and the second conveyor.

[0205] Item 54. The assembly of any preceding or following item, further comprising a second plurality of forming tools attached to the second conveyor and forming the product as it is transported along the first conveyor and the second conveyor.

[0206] Item 55. The assembly of any preceding or following item, further comprising a cooling chamber for cooling the product while it is being transported and formed.

[0207] Item 56. A system comprising: a dispenser of multiple strands of molten thermoplastic resin; and an assembly according to any preceding or following item oriented relative to the dispenser to receive, convey, and shape the multiple strands.

[0208] Item 57. The assembly of any preceding or following item, further comprising the second subassembly.

[0209] Item 58. The assembly of any preceding or following item, further comprising a cooling chamber for cooling the product while it is being transported and formed.

[0210] Item 59. A system comprising: a dispenser for a plurality of strands of molten thermoplastic resin; and an assembly according to any preceding or following item oriented relative to the dispenser to receive, convey, and shape the plurality of strands.

[0211] Item 60. The assembly of any preceding or following item, further comprising the third subassembly.

[0212] Item 61. The assembly of any preceding or following item, further comprising a second actuator array including one or more second actuators, each deployable to contact the product, the second actuator array spaced apart from the first actuator array such that the product is conveyed therebetween, and the controller further configured to control a position of each second actuator to contact and shape the product as it is moved past the second actuator array.

[0213] Item 62. The assembly of any preceding or following item, further comprising a third actuator array including one or more third actuators, each deployable to contact the product, the third actuator array spaced apart from the first actuator array and the second actuator array such that the product is conveyed therebetween, and the controller is further configured to control a position of each third actuator to contact and shape the product as it is moved past the third actuator array.

[0214] Item 63. The assembly of any preceding or following item, further comprising a fourth actuator array including one or more fourth actuators, each fourth actuator deployable to contact the product, the fourth actuator array spaced apart from the first actuator array, the second actuator array, and the third actuator array so that the product is conveyed therebetween, and the controller is further configured to control a position of each fourth actuator to contact and shape the product as it is moved past the fourth actuator array.

[0215] Item 64. The assembly of any preceding or following item, wherein the first actuator array, the second actuator array, the third actuator array, and the fourth actuator array are positioned to surround the product.

[0216] Item 65. The assembly of any preceding or following item, further comprising a fluid chamber for cooling the product while it is being molded.

[0217] Item 66. The assembly of any preceding or following item, further comprising a flexible layer positioned between at least one of the actuators and the product.

[0218] Item 67. The assembly of any preceding or following item, wherein the controller is further configured to control a stroke distance of at least one of the actuators when forming the product.

[0219] Item 68. The assembly of any preceding or following item, wherein the controller is further configured to control the actuation time of at least one of the actuators in forming the product.

[0220] Item 69. The assembly of any preceding or following item, wherein the controller is further configured to receive a signal indicative of a feed rate of the product and to control at least one of the actuators based on the signal.

[0221] Item 70. The assembly of any preceding or following item, wherein each actuator comprises a linear actuator.

[0222] Item 71. The assembly of any preceding or following item, wherein each actuator comprises a head.

[0223] Item 72. The assembly of any preceding or following item, wherein each head of the actuator comprises rubber.

[0224] Item 73. The assembly of any preceding or following item, wherein each actuator array includes a row of multiple actuators.

[0225] Item 74. The assembly of any preceding or following item, wherein each actuator array includes one or more layers of columns.

[0226] Item 75. An assembly according to any preceding or succeeding item, wherein the layers of the row are positioned to be stacked in the direction of travel of the product.

[0227] Item 76. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; and an assembly according to any preceding or following item, the assembly being oriented relative to the dispenser to receive and form the multiple strands as the multiple strands pass through the assembly.

[0228] Item 77. The assembly of any preceding or following item, further comprising the fourth subassembly.

[0229] Item 78. The assembly of any preceding or following item, wherein the nozzle is oriented to direct a fluid stream toward the product in a single direction.

[0230] Item 79. The assembly of any preceding or following item, wherein the nozzle is oriented to direct fluid flow toward the product in at least two different directions.

[0231] Item 80. The assembly of any preceding or following item, wherein at least one nozzle of the one or more nozzles is a diverging nozzle.

[0232] Item 81. The assembly of any preceding or following item, wherein at least one nozzle of the one or more nozzles is a convergent nozzle.

[0233] Item 82. The assembly of any preceding or following item, wherein at least one nozzle of the one or more nozzles is a diverging nozzle and at least another nozzle of the one or more nozzles is a converging nozzle.

[0234] Item 83. The assembly of any preceding or following item, further comprising a pump fluidly connected to the one or more nozzles.

[0235] Item 84. A system comprising: a dispenser for multiple strands of molten thermoplastic resin; and an assembly according to any preceding or following item, the assembly being oriented relative to the dispenser to receive and form the multiple strands as they pass through the assembly.

[0236] Item 85. A system comprising a dispenser for multiple strands of molten thermoplastic resin, a fluid bath, and the assembly of any of the preceding items, wherein the assembly is at least partially submerged within the fluid bath.

[0237] Item 86. Any one of the preceding items 1 to 85 in any combination.

[0238] While exemplary embodiments have been described above, these embodiments are not intended to represent all possible forms according to the present disclosure. In that regard, it is understood that the terms used herein are terms of description rather than limitation, and that various changes can be made without departing from the spirit and scope of the present disclosure. In addition, features of various embodiments can be combined to form further embodiments according to the present disclosure.

Claims

1. Dispensing a plurality of strands of molten polymer material; applying a force to the plurality of strands via one or more forming assemblies; A method comprising:

2. The method of claim 1 , wherein the forming assembly comprises at least one of one or more nozzles, one or more forming conveyors, or one or more actuator assemblies.

3. 3. The method of claim 2, further comprising at least one of applying the force to the plurality of strands by directing one or more fluid jets from the one or more nozzles, applying the force to the plurality of strands by conveying the plurality of strands along the one or more forming conveyors, or applying the force to the plurality of strands by actuating one or more actuators to contact the plurality of strands.

4. moving the plurality of strands through a fluid bath; applying the force to the plurality of strands via the one or more forming assemblies while the plurality of strands is at least partially submerged in the fluid bath; The method of any one of claims 1 to 3, further comprising:

5. The method of claim 4 further comprising cooling the plurality of strands in the fluid bath.

6. The method of any one of claims 1 to 5, further comprising cutting the contoured, connected filament structure to form at least one of a vehicle interior part or a one-piece nonwoven cushion.

7. heating said polymeric material to a molten state such that said polymeric material becomes said molten polymer; introducing the molten polymer into a die plate having a plurality of holes disposed therethrough such that the molten polymer travels through the holes to form the plurality of strands into molten polymer filaments; introducing the molten polymer filaments into a tank to cool the molten polymer filaments; applying a fluid stream to the molten polymer filaments through the one or more forming assemblies to apply the force after the molten polymer filaments are introduced into the bath, thereby imparting a desired shape to the molten polymer filaments and forming the connected filament structure having the desired shape; The method of any one of claims 1 to 3, further comprising:

8. The method of claim 7 , wherein the reservoir contains a liquid and the fluid stream comprises the liquid.

9. 9. The method of claim 7, wherein applying the fluid stream to the molten polymer filaments comprises moving the fluid stream through a nozzle before the fluid stream contacts the molten polymer filaments.

10. 10. The method of claim 9, wherein the nozzle is positioned 10 mm to 15 mm from a surface of the molten polymer filament.

11. 11. The method of any one of claims 7 to 10, further comprising applying a plurality of said fluid streams to said molten polymer filaments after said molten polymer filaments are introduced into said tank.

12. The method of claim 11 , wherein the fluid stream is applied to the molten polymer filaments in a single direction.

13. The method of claim 12 , wherein the fluid stream is applied to the molten polymer filaments in at least two different directions.

14. heating a polymeric material to a molten state to form said molten polymeric material; extruding the molten polymer material to form a plurality of molten polymer filaments into the plurality of strands; cooling the molten polymer material in a fluid bath to create a connected filament structure; applying a fluid flow to apply said force to said molten polymer filaments in said fluid bath via said one or more forming assemblies so that said connected filament structure has a desired shape as a contoured connected filament structure; The method of any one of claims 1 to 3, further comprising:

15. 15. The method of claim 14, wherein the connected filament structure is a cushion blank for a vehicle seat and the desired shape includes two bolsters positioned on opposite sides of the cushion blank.

16. 16. The method of claim 14 or 15, further comprising applying a plurality of said fluid streams to said molten polymer filaments in said fluid bath in at least one direction.

17. The method of claim 16 , wherein at least one of the fluid streams is applied through a nozzle.

18. The method of claim 17, wherein the nozzle is a diverging nozzle.

19. 16. The method of claim 14, wherein each of the fluid streams is applied to the molten polymer filaments through a respective nozzle.

20. The method of claim 19 , wherein at least one of the nozzles is a convergent nozzle.

21. The method of any one of claims 14 to 20, wherein the fluid reservoir contains a liquid and the fluid stream comprises the liquid.

22. heating a polymeric material to form a molten polymeric material; forming a plurality of molten polymer filaments from the molten polymer material into the plurality of strands; cooling the molten polymeric material in a fluid bath; directing a fluid stream at the molten polymer material in the fluid bath and applying the force through the one or more forming assemblies to cause the molten polymer to assume a desired shape; The method of any one of claims 1 to 3, further comprising:

23. 23. The method of claim 22, wherein a connected filament structure is formed by cooling the molten polymer in the fluid bath, and the desired shape is imparted to the connected filament structure as a contoured connected filament structure by directing the fluid stream at the molten polymer in the fluid bath.

24. 24. The method of claim 22 or 23, further comprising directing a plurality of said fluid streams into said molten polymeric material in said fluid bath in at least one direction.

25. 25. The method of claim 24, wherein the connected filament structure is a cushion blank for a vehicle seat and the desired shape includes two bolsters positioned on opposite sides of the cushion blank.

26. the molten polymeric material is a molten thermoplastic resin and the contoured interconnected filament structure is a contoured one-piece mesh product; 4. The method of claim 1, further comprising conveying the plurality of strands along at least one forming conveyor of the one or more forming assemblies while applying the force, to form the plurality of strands into the contoured, one-piece mesh product.

27. 27. The method of claim 26, further comprising conveying the plurality of strands as the contoured, one-piece mesh product in a plurality of forming conveyors.

28. 28. The method of claim 27, further comprising translating at least one of the forming conveyors to vary the spacing between the forming conveyors while transporting and forming the strands.

29. The method of any one of claims 26 to 28, further comprising shaping the plurality of strands with at least one shaping tool attached to the at least one shaping conveyor.

30. 30. The method of any one of claims 26-29, further comprising applying resistance to the flow of the plurality of strands, thereby buckling the plurality of strands, wherein the buckled strands intersect as a unitary nonwoven body.

31. 31. The method of any one of claims 26 to 30, further comprising cooling the plurality of strands to bond them into the contoured, unitary mesh product.

32. 32. The method of any one of claims 26 to 31, further comprising cooling the plurality of strands while forming the plurality of strands.

33. The method of any one of claims 26 to 32, further comprising cooling the plurality of strands in a cooling chamber.

34. the molten polymeric material is a molten thermoplastic resin and the contoured interconnected filament structure is a contoured one-piece mesh product; 4. The method of claim 1, further comprising actuating one or more actuators of the one or more forming assemblies to contact the plurality of strands, thereby applying the force and forming the plurality of strands into the contoured, one-piece mesh product.

35. 35. The method of claim 34, further comprising conveying the plurality of strands as the contoured, one-piece mesh product past the one or more actuators.

36. 36. The method of claim 35, further comprising actuating a first actuator of the one or more actuators and a second actuator of the one or more actuators opposite the first actuator to vary spacing between the plurality of strands while shaping them.

37. 37. The method of any one of claims 34-36, further comprising applying resistance to the flow of the plurality of strands, thereby buckling the plurality of strands, wherein the buckled strands intersect as a unitary nonwoven body.

38. 38. The method of any one of claims 34 to 37, further comprising cooling the plurality of strands to bond them into the contoured, unitary mesh product.

39. 39. The method of any one of claims 34 to 38, further comprising cooling the plurality of strands while forming the plurality of strands.

40. 40. The method of any one of claims 34 to 39, further comprising cooling the plurality of strands in a fluid chamber.

41. An interior vehicle component formed by the method of any one of claims 1 to 40.

42. 42. The vehicle interior part of claim 41, wherein the vehicle interior part is a cushion for a vehicle seat and includes two bolsters positioned on opposite sides of the cushion.

43. A product produced according to the method of any one of claims 1 to 40.

44. the contoured, connected filament structure forms the article; The method of any one of claims 1 to 40, wherein the method further comprises installing the product as a seat cushion on a seat frame.

45. 45. A seat assembly manufactured according to the method of claim 44.

46. Dispensing a plurality of strands of molten thermoplastic resin; forming the plurality of strands into a contoured, unitary mesh product by applying a force to the plurality of strands through one or more forming assemblies, the forming assemblies comprising at least one of one or more nozzles, one or more forming conveyors, and / or one or more actuator assemblies; A product manufactured according to a method comprising:

47. 47. The product of claim 46, wherein the method further comprises shaping the plurality of strands by actuating the one or more actuators of the one or more forming assemblies to contact the plurality of strands, thereby forming the plurality of strands into a contoured, one-piece mesh product.

48. 47. The product of claim 46, wherein the method further comprises shaping the plurality of strands by conveying the plurality of strands through the one or more forming conveyors of the one or more forming assemblies to contact the plurality of strands, thereby forming the plurality of strands into a contoured, one-piece mesh product.

49. The method further includes shaping the plurality of strands by directing one or more fluid jets through the one or more nozzles of the one or more forming assemblies toward and contacting the plurality of strands, thereby forming the plurality of strands into a contoured, one-piece mesh product.

50. 50. The article of manufacture of any one of claims 46 to 49, further comprising an integral nonwoven cushion.

51. 1. An assembly comprising: (i) a first subassembly, a conveyor for transporting products; a plurality of forming tools attached to the conveyor for forming the product as it is conveyed along the conveyor; a first subassembly comprising: (ii) a second subassembly, a pair of spaced apart conveyors for conveying the products therebetween; an actuator that cooperates with the pair of conveyors to vary the spacing between the pair of conveyors to shape the product as it is conveyed; a second subassembly comprising: (iii) a third subassembly, an actuator array including one or more actuators, each actuator deployable to contact the product; a controller configured to control the position of each actuator to contact and shape the product as it is moved past the array of actuators; and / or a third subassembly comprising: (iv) a fourth subassembly comprising one or more nozzles positioned to direct fluid toward the product to shape the product as it is moved past the one or more nozzles; An assembly comprising at least one of:

52. 52. The assembly of claim 51 further comprising the first subassembly.

53. 53. The assembly of claim 52, further comprising a second conveyor for conveying the product, the second conveyor being spaced from the first conveyor and conveying the product between the first conveyor and the second conveyor.

54. 54. The assembly of claim 53, further comprising a second plurality of forming tools attached to the second conveyor for forming the product as it is transported along the first and second conveyors.

55. 55. The assembly of any one of claims 52 to 54, further comprising a cooling chamber for cooling the product while it is being transported and formed.

56. a dispenser for a plurality of strands of molten thermoplastic resin; an assembly according to any one of claims 52 to 55, oriented relative to the dispenser to receive, convey and shape the plurality of strands; A system comprising:

57. 52. The assembly of claim 51 further comprising the second subassembly.

58. 58. The assembly of claim 57, further comprising a cooling chamber for cooling the product while it is being transported and formed.

59. a dispenser for a plurality of strands of molten thermoplastic resin; An assembly according to any one of claims 56 to 58, oriented relative to the dispenser to receive, convey and shape the plurality of strands; A system comprising:

60. 52. The assembly of claim 51 further comprising the third subassembly.

61. a second actuator array including one or more second actuators, each second actuator deployable to contact the product, the second actuator array spaced apart from the first actuator array such that the product is transported therebetween; 61. The assembly of claim 60, wherein the controller is further configured to control a position of each second actuator to contact and shape the product as the product is moved past the second array of actuators.

62. a third actuator array including one or more third actuators, each third actuator deployable to contact the product, the third actuator array spaced apart from the first actuator array and the second actuator array such that the product is transported therebetween; 62. The assembly of claim 61, wherein the controller is further configured to control a position of each third actuator to contact and shape the product as the product is moved past the third actuator array.

63. a fourth actuator array including one or more fourth actuators, each fourth actuator deployable to contact the product, the fourth actuator array spaced apart from the first actuator array, the second actuator array, and the third actuator array such that the product is transported therebetween; 63. The assembly of claim 62, wherein the controller is further configured to control a position of each fourth actuator to contact and shape the product as the product is moved past the fourth actuator array.

64. 64. The assembly of claim 63, wherein the first actuator array, the second actuator array, the third actuator array, and the fourth actuator array are positioned to surround the product.

65. 65. An assembly according to any one of claims 60 to 64, further comprising a fluid chamber for cooling the product whilst it is being moulded.

66. 66. An assembly according to any one of claims 60 to 65, further comprising a flexible layer positioned between at least one of the actuators and the product.

67. 67. An assembly according to any one of claims 60 to 66, wherein the controller is further configured to control a stroke distance of at least one of the actuators when forming the product.

68. 68. An assembly according to any one of claims 60 to 67, wherein the controller is further configured to control the actuation time of at least one of the actuators in forming the product.

69. 69. An assembly according to any one of claims 60 to 68, wherein the controller is further configured to receive a signal indicative of a rate at which the product is dispensed, and to control at least one of the actuators based on the signal.

70. 70. An assembly according to any one of claims 60 to 69, wherein each actuator comprises a linear actuator.

71. An assembly according to any one of claims 60 to 70, wherein each actuator comprises a head.

72. 72. The assembly of claim 71, wherein each head of the actuator comprises rubber.

73. 73. An assembly according to any one of claims 60 to 72, wherein each actuator array comprises a row of actuators.

74. 74. An assembly according to any one of claims 60 to 73, wherein each actuator array comprises one or more layers of columns.

75. 75. The assembly of claim 74, wherein the layers of the row are positioned to be stacked in the direction of travel of the product.

76. a dispenser for a plurality of strands of molten thermoplastic resin; 76. The assembly of any one of claims 60 to 75, oriented relative to the dispenser to receive and shape the plurality of strands as the plurality of strands pass through the assembly; A system comprising:

77. 52. The assembly of claim 51 further comprising the fourth subassembly.

78. 78. The assembly of claim 77, wherein the nozzle is oriented to direct a fluid stream toward the product in a single direction.

79. 78. The assembly of claim 77, wherein the nozzle is oriented to direct a fluid stream toward the product in at least two different directions.

80. 80. An assembly according to any one of claims 77 to 79, wherein at least one nozzle of the one or more nozzles is a diverging nozzle.

81. 80. An assembly according to any one of claims 77 to 79, wherein at least one nozzle of the one or more nozzles is a convergent nozzle.

82. 80. An assembly according to any one of claims 77 to 79, wherein at least one nozzle of the one or more nozzles is a diverging nozzle and at least another nozzle of the one or more nozzles is a converging nozzle.

83. 82. The assembly of any one of claims 77 to 81, further comprising a pump fluidly connected to the one or more nozzles.

84. a dispenser for a plurality of strands of molten thermoplastic resin; 84. The assembly of any one of claims 77 to 83, oriented relative to the dispenser to receive and shape the plurality of strands as the plurality of strands pass through the assembly; A system comprising:

85. a dispenser for a plurality of strands of molten thermoplastic resin; a fluid bath; The assembly of claim 51; A system comprising: The assembly is at least partially submerged within the fluid bath.

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