Seat support and vehicle seat

Abstract

Provides seat support. [Solution] The seat support comprises a plastic mesh base (232) including a first plurality of three-dimensional filament rings (254), a first edge (234), and a second edge (236); a first plastic mesh bolster (242) including a second plurality of three-dimensional filament rings (250); and a second plastic mesh bolster (244) including a third plurality of three-dimensional filament rings (252). The first plastic mesh bolster is attached to the plastic mesh base at its first edge, and the second plastic mesh bolster is attached to the plastic mesh base at its second edge. The first and second plastic mesh bolsters are attached to the plastic mesh base by at least one of hook-and-loop fasteners, adhesive, retaining clips, and hog rings.

Description

Technical Field

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

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

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

Brief Description of the Drawings

[0004] [Figure 1] A perspective cross - sectional view of a seat assembly according to some embodiments. [Figure 2] An exploded perspective view of multiple layers of a seat assembly according to some embodiments. [Figure 3] A side cross - sectional view of a seat assembly according to some embodiments. [Figure 3B] A diagram showing a method according to some embodiments. [Figure 4] A front perspective view of a seat assembly according to some embodiments. [Figure 5] Figure 4 is a front perspective view of the seat assembly cushion. [Figure 6] Figure 5 is a side view of the cushion. [Figure 7] Figure 5 is a schematic front view of the cushion. [Figure 8] Figure 5 is a front perspective view of a portion of the cushion. [Figure 9] This is a side view showing a portion of a cushion according to several embodiments in a first position. [Figure 10] This is another side view showing a portion of the cushion in Figure 9 at a second position. [Figure 11] This is a front view showing a partially disassembled cushion according to several embodiments. [Figure 12] Figure 11 is a rear view of the cushion. [Figure 13] This is another rear view showing the cushion in Figure 11 after the intermediate assembly process. [Figure 14] This is another rear view showing the cushion from Figure 11 after a different assembly process. [Figure 15] This is a front view showing the cushion in Figure 11 after the assembly process shown in Figures 11 to 14. [Figure 16] This is a side view of a cushion according to several embodiments. [Figure 16B] This figure shows a method according to several embodiments. [Figure 16C] This figure shows a method according to several embodiments. [Figure 16D] This figure shows a method according to several embodiments. [Figure 17] This is a perspective view of a vehicle seat. [Figure 18A] This is a front view of a vehicle seat cushion component having a plastic mesh-like side bolster. [Figure 18B] This is a front view of a vehicle seat cushion component having a plastic mesh-like side bolster. [Figure 19A]This is a front view of a vehicle seat cushion component having a plastic mesh-like side bolster and one or more surface layers. [Figure 19B] This is a front view of a vehicle seat cushion component having a plastic mesh-like side bolster and one or more surface layers. [Figure 20] A perspective view of a vehicle seat incorporating a pair of bolster assemblies sewn into the trim cover. [Figure 21A] This is a top view of a vehicle seat component, including a pair of bolster assemblies sewn onto the trim cover. [Figure 21B] This is a cross-sectional view of a vehicle seat component, including a pair of bolster assemblies sewn onto a trim cover. [Figure 22] This is a perspective view of a vehicle seat. [Figure 23A] This is a front view of a vehicle seat cushion component having a foam side bolster. [Figure 23B] This is a front view of a vehicle seat cushion component having a foam side bolster. [Figure 24A] This is a front view of a vehicle seat cushion component having a foamed side bolster and one or more surface layers. [Figure 24B] This is a front view of a vehicle seat cushion component having a foamed side bolster and one or more surface layers. [Figure 25] This is a perspective view of a seat assembly according to several embodiments. [Figure 26] Figure 25 is a partial perspective view of the non-foamed cushion of the seat assembly. [Figure 27] Figure 25 is a partial top view of the retaining parts attached to the cushion and other seat components. [Figure 27B] This figure shows a method according to several embodiments. [Figure 28] This is a perspective view showing a seat assembly according to several embodiments. [Figure 29] This is a partial diagram showing a portion of a cushion used with the seat assembly of Figure 28, according to several embodiments. [Figure 30] This is a schematic diagram showing the manufacturing process of the cushion in Figure 29 according to several embodiments. [Figure 31] This is a top view showing the extrusion direction used in conjunction with the manufacturing process shown in Figure 29. [Figure 32] This is a partial side schematic view showing a cushion in a first configuration formed using the die of Figure 31, used in conjunction with the seat assembly of Figure 28, according to several embodiments. [Figure 33] This is a schematic side view showing the cushion in Figure 32, which is part of the second configuration. [Figure 34] This is a schematic partial side view showing the cushion of Figure 32, which has an insert. [Figure 35] This is a top view showing another part or example used in conjunction with the manufacturing process shown in Figure 29. [Figure 36] This is a partial side schematic view showing a cushion in a first configuration formed using the die of Figure 35, used in conjunction with the seat assembly of Figure 28, according to several embodiments. [Figure 37] This is a schematic side view showing the cushion in Figure 36, which is part of the second configuration. [Figure 38] This figure shows a method according to several embodiments. [Modes for carrying out the invention]

[0005] The embodiments are described below with reference in detail, examples of which are shown in the accompanying drawings. The following detailed description includes numerous specific details to provide a complete understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments can be carried out without these specific details. In other instances, known methods, procedures, components, circuits, and networks are not described in detail so as not to unnecessarily obscure the aspects of the embodiments.

[0006] It should be understood that the embodiments disclosed are merely illustrative and that various alternative forms are possible. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to illustrate the details of specific parts. Therefore, the details relating to specific structures and functions disclosed herein should not be construed as limiting, but merely as representative grounds to teach those skilled in the art how to employ the embodiments provided herein in various ways.

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

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

[0009] The terminology used in this specification to describe various embodiments is intended solely to describe specific embodiments and is not intended to limit them. Where used in the descriptions of various embodiments and in the appended claims, the singular forms "one," "one," and "the" are intended to include the plural form unless otherwise explicitly indicated in the context.

[0010] As used herein, the term "and / or" refers to and encompasses all possible combinations of one or more of the related enumerated items. For example, the term "and / or" means that all or only one of the elements of the group described above may be present. For example, "A and / or B" means "A only, B only, or both A and B." In the case of "A only," the term also encompasses the possibility that B is not present, i.e., "A only, and B not."

[0011] It should be further understood that, as used herein, the terms “includes” and / or “comprises” specify the presence of the described features, integers, processes, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, integers, processes, operations, elements, parts, and / or groups thereof.

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

[0013] Except as provided in the examples or otherwise expressly indicated, all quantities in this specification indicating the amount of material or the conditions of reaction and / or use should be understood to be modified by the word “about” when describing the broadest scope of the invention. It is generally preferred to carry out the invention within the limits of the numerical values ​​stated. Furthermore, unless otherwise specified, percentages, parts, and ratios are given by weight; the term "polymer" includes "oligomers," "copolymers," "terpolymers," etc.; the molecular weight provided for any polymer refers to the weight-average molecular weight unless otherwise indicated; any description of a group or class of materials as suitable or preferred for a given purpose relating to the present invention implies that any two or more mixtures of members of that group or class are equally suitable or preferred; the description of a component in chemical terms refers to the component when added to any combination identified in the description and does not necessarily exclude chemical interactions between components of a mixture once mixed; the initial definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation herein and to the usual grammatical variations of the initially defined abbreviation; unless otherwise specified, the measurements of properties are determined by the same techniques as previously or later referenced for the same property.

[0014] Where used herein, the term “about” means that the quantity or value in question may be a specific value or any other value in its vicinity. Generally, the term “about” referring to a particular value is intended to indicate a range of ±5% of that value. As one example, the phrase “about 100” refers to a range of 100 ± 5, i.e., 95 to 105. Generally, where the term “about” is used, it can be expected that similar results or effects according to the present invention can be obtained within a range of ±5% of the indicated value.

[0015] Since certain parts and / or conditions can certainly change, it should also be understood that the present invention is not limited to the specific embodiments and methods described below. Furthermore, the terminology used herein is used solely for the purpose of describing specific embodiments of the present invention and is not intended to limit them in any way.

[0016] The term "comprising" is synonymous with "including," "having," "containing," or "characterized by." These terms are inclusive and unrestricted and do not exclude additional, undescribed elements or methods or processes.

[0017] The phrase "consisting of" excludes any element, process, or component not specified in the claim. If this phrase appears in a section of the claim rather than immediately following the preamble, it limits only the elements described in that section, and does not exclude other elements as a whole from the claim.

[0018] The phrase "consisting essentially of" limits the scope of the claims to any material or process that does not substantially affect the basic and novel features (or multiple features) of the claimed subject matter.

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

[0020] With respect to the terms “equipped with,” “consisting of,” and “essentially consisting of,” if any of these three terms is used herein, the subject matter of this disclosure may include the use of any of the other two terms.

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

[0022] The terms “substantially,” “generally,” or “about” may be used herein to describe embodiments disclosed or claimed. The term “substantially” may modify a value or relative feature disclosed or claimed herein. In such cases, “substantially” may mean that the value or relative feature it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of that value or relative feature.

[0023] Furthermore, a range of integers explicitly includes all intervening integers. For example, the integer range 1 to 10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4, ... 97, 98, 99, and 100. Likewise, if any range is specified, an intervening number that is the increment obtained by dividing the difference between the upper and lower bounds by 10 can be adopted as an alternative upper or lower bound. For example, if the range is 1.1 to 2.1, the following numbers can be selected as the lower or upper bound: 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0.

[0024] When referring to quantities, in one definition, the term “less than” includes an unincluded lower limit that is 5 percent of the number preceding “less than.” For example, “less than 20” in one definition includes 1 as the unincluded lower limit. Therefore, in this definition, “less than 20” includes the range from 1 to 20. In another definition, the term “less than” includes an unincluded lower limit that is 20 percent, 10 percent, 5 percent, or 1 percent of the number preceding “less than” in ascending order of preference.

[0025] Seat assemblies and vehicle seat assemblies are designed and manufactured in accordance with a variety of specifications, including support, comfort, performance, heating, ventilation, cooling, and adjustability. Seat assemblies often comprise a frame and various layers of foam with different densities to accommodate the applicable load distribution across the seat assembly.

[0026] Figure 1 shows a seat assembly 20 according to one embodiment. The seat assembly 20 is shown as a vehicle seat that can be used as a seat assembly in land vehicles, aircraft, ships, etc. The seat assembly 20 can be used in any row within a vehicle. Alternatively, the seat assembly 20 can also be used as an office chair or any personal chair. The seat assembly 20 eliminates conventional foam in order to improve support and comfort while reducing cost, materials, and dimensions. The seat assembly 20 can also utilize recycled materials manufactured for further recycling when the seat assembly 20 is no longer in use.

[0027] The seat assembly 20 includes a seat base 22 sized to receive a seated occupant and support the occupant's pelvis and thighs. The seat assembly 20 also includes a seat back 24 sized to extend upright from the seat base 22 and support the occupant's back. A headrest may be supported above and above the seat back 24 to support the occupant's head. The seat base 22 is adapted to be supported by a support surface below. In the illustrated embodiment, the seat assembly 20 includes a pair of rails 28 for mounting the seat base 22 to the vehicle floor so that it can be adjusted fore and aft relative to the vehicle floor. The seat back 24 may also be adjustable to recline relative to the seat base 22. The headrest may also be adjustable in height, tilt, and fore and aft directions. Other adjustments may be provided as are known in the art.

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

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

[0030] The seat assembly 20 is formed without foam to improve comfort, performance, compactness, and recyclability while reducing the machinery and equipment costs associated with its manufacture. For example, the seat assembly 20 includes a seat base support 36 that provides a seat base cushion for the seat base 22. The seat base support 36 is formed from multiple stacked layers of non-foam material. The seat back 24 includes a seat back support 38 similarly formed from stacked layers of non-foam material. Similarly, the headrest may also include a headrest support formed from stacked layers of non-foam material.

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

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

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

[0034] After layers 40, 42, 44, 46, 48, 50, and 52 are unwound as sheets 40, 42, 44, 46, 48, 50, and 52, the sheets 40, 42, 44, 46, 48, 50, and 52 are then die-cut into the shape of seat support layers 40, 42, 44, 46, 48, 50, and 52 to collectively provide the contour of the seat base 22. The seat support layers 40, 42, 44, 46, 48, 50, and 52 are then stacked and connected or joined together. Seat support layers 40, 42, 44, 46, 48, 50, and 52 can be welded, sewn, fastened, bonded or otherwise connected to consecutively adjacent seat support layers 40, 42, 44, 46, 48, 50, and 52. Alternatively, sheets 40, 42, 44, 46, 48, 50, and 52 may be stacked or stacked and joined before the cutting operation. The cutting operation may be carried out by one or more dies. The machinery equipment cost for the die-cutting dies offers a reduction in capital costs compared to dedicated molding dies. Alternatively, machinery equipment costs can be reduced by employing robotic laser cutting or other flexible automated machine operations that can be programmed to cut out various sheet configurations.

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

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

[0037] Referring again to Figure 1, once the stacked layers 40, 42, 44, 46, 48, 50, and 52 are assembled, the seat supports 36, 38 are installed within the seat assembly 20. Trim covers 60, 62 are provided on top of each seat support 36, 38 to accommodate and conceal them.

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

[0039] The seat assembly 20 is lighter than comparable seats made of foam cushioning material. The seat assembly 20 is also more compact in dimensions, such as having a depth of 35-40 mm, while providing similar or improved comfort. The target comfort layer is provided and it can be easily redesigned for future models or options without additional mechanical equipment costs.

[0040] Figure 3B shows Method 400 in several embodiments. Method 400 is used to manufacture seat assemblies (e.g., seat assemblies 20, 120, 210, 310, 410, 520, 620), which may be vehicle seats, office chairs, personal chairs, etc. In various examples, Method 400 may have more or fewer steps than those described below, and the various steps may be performed sequentially or simultaneously in a different order. Method 400 may be a method for manufacturing products that may be vehicle seats, office chairs, personal chairs, cushions, seat supports, seat base cushions, seat back cushions, headrests, etc.

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

[0042] In some embodiments, Method 400 includes unwinding a third sheet of a third material, which may be generally planar within manufacturing tolerances, having a density lower than that of the second material and capable of providing a density and stiffness transition from comfort support at the passenger contact surface in the comfort layer to structural support in the base layer. The third material may or may not have foam and may be rubber, carpet, regenerated pricked cotton wool, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, recycled material sheets and / or each unwound from a roll of material. Each of the rolls of material may be a roll of material readily available on the market, such as materials used in vehicle interiors, flooring, acoustics, etc. Method 400 includes cutting a third seat support layer (e.g., intermediate layer 46) from a third sheet, which may be die-cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automated mechanical operations, and placing the third seat support layer (e.g., intermediate layer 46) on a second seat support layer (e.g., intermediate layer 44).

[0043] In some embodiments, Method 400 includes joining a second seat support layer (e.g., an intermediate layer 44) to a first seat support layer (e.g., an intermediate layer 42). Joining may be provided by retaining clips having ends embedded in foam and retaining clip ends attached to a plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog ringing, single-sided or double-sided retaining clips, welding, sewing, fastening, bonding, heat riveting and / or other retaining methods.

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

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

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

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

[0048] In some embodiments, multiple stacked layers (e.g., intermediate layers 42-50) are connected together, and the connection may be by retaining clips having ends embedded in the layers and retaining clip ends attached to a plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog rings, single-sided or double-sided retaining clips, joining, welding, sewing, fastening, bonding, heat riveting and / or holding.

[0049] In some embodiments, each consecutive pair of multiple stacked layers (e.g., intermediate layers 42-50) (e.g., layers 42 and 44; layers 46 and 48) are joined together, and the joining may be by retaining clips having ends embedded in the layers and retaining clip ends attached to a plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog rings, single-sided or double-sided retaining clips, welding, sewing, fastening, bonding, heat riveting and / or retention.

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

[0051] In some embodiments, the multiple stacked layers (e.g., intermediate layers 42-50) further include rubber, carpet, regenerated cotton fibers, polyethylene terephthalate, or polypropylene.

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

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

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

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

[0056] The techniques described above for Method 400 can be optionally combined with one or more elements of the methods described later. For example, this method can be used with one or more of the methods 1600, 1650, 1680, 2700, and 3800.

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

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

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

[0060] In some embodiments, the seat assembly comprises a seat frame, a wire suspension mat, a base material and / or panels, which may be a stamped steel alloy, a fiber-reinforced polymer or any suitable structural material, the base material (e.g., layer 40) being attached to the seat frame.

[0061] A seat support (e.g., seat support 36, 38 and / or 54) is described, which may be a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, an area, a part, etc. The seat support (e.g., seat support 36, 38 and / or 54) may be generally planar within manufacturing tolerances and may or may not have foam, and comprises a plurality of flat layers (e.g., layers 40-50) which may be rubber, carpet, needle-punched cotton recycled wool, polyethylene terephthalate, polypropylene, ethylene propylene diene monomer rubber, thermoplastic polyurethane, foamed polyvinyl chloride, recycled material sheets and / or each unwound from a roll of material. Each of the rolls of material may be a roll of material readily available on the market, such as materials used for vehicle interiors, flooring, acoustics, etc. Multiple flat layers, which may be punched steel alloy, fiber-reinforced polymer, or any suitable structural material, are attached to a seat frame, wire suspension mat, base material, and / or panel to support the occupant on the seat frame, and the multiple flat layers (e.g., layers 40-50) are stacked on top of each other, and the multiple stacked layers (e.g., layers 40-50) differ in density such that the density increases continuously from the occupant support surface (e.g., layer 50) to the base layer (e.g., 40), thereby providing a transition in density and stiffness from comfort support at the occupant contact surface in the comfort layer to structural support in the base layer, which may contain high-density materials such as elastomers, ethylene propylene diene monomer rubber, thermoplastic polyurethane, and / or foamed polyvinyl chloride. The base layer can provide a base material, i.e., shell, for the intermediate and comfort layers.

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

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

[0064] Figures 5 to 7 show the seat base cushion 122 as it has been removed from the seat assembly 120. The seat base cushion 122 has an overall integrated seat cushion 122 design. Such a design is conventional, as seat cushion designs are typically designed with the final product in mind. Subsequently, modifications are incorporated to support the associated manufacturing processes.

[0065] Referring here to Figure 8, a portion of the seat cushion 122 is partially shown detached from the seat assembly 120. The seat cushion 122 is formed from a plurality of filamentous bodies 128 or three-dimensional filament rings of extruded foamed thermoplastic resin or polymer. The seat cushion 122 is also formed with a base layer 130 bonded to and / or integrally formed with the plurality of filamentous bodies 128. The extruded mesh cushion 122 is readily manufactured to have a rectangular cross-section or a constant thickness.

[0066] Referring again to Figures 5-7, the seat cushion 122 is redesigned into three layers, sections, or cushion sections 130, 132, and 134. The cushion sections 130, 132, and 134 are stacked collectively on top of each other to provide the seat cushion 122 collectively. The sections 130, 132, and 134 are designed to have a common maximum thickness so that they can be integrally formed as a single sheet of the extruded mesh body 128 and then stacked. In addition, the sections 130, 132, and 134 can be pivotably interconnected so that they can stack on top of each other. Referring to Figure 7, the outer parallelogram of the central section 132 is designed to pivot upward to coincide with the lateral outer surface of the upper section 134.

[0067] Figure 9 shows a side view of a portion of a cushion 136 according to one embodiment. The cushion 136 comprises a pair of cushion portions 138 and 140 integrally formed as a single mesh-like body 128 of extruded thermoplastic resin. A pair of recesses 142 are formed on the surface of the foam to define a hinge 144 that pivotally connects the cushion portions 138 and 140. As shown in Figure 10, the cushion portions 138 and 140 can be pivoted around the hinge 144. Any number of recesses 142 and any range of pivoting can be used to pivot and / or stack the cushion portions 138.

[0068] Figure 11 shows the seat back cushion 124 in a partially removed state. The seat back cushion 124 is formed from a single sheet of extruded thermoplastic mesh 128 having a uniform thickness. The seat back cushion 124 is shown after secondary molding operations such as cutting and assembling various cushion details. The cutting operations are performed by automated machinery such as waterjet cutting, laser cutting, and die-cutting. The seat back cushion 124 comprises three cushion sections 146, 148, and 150.

[0069] The central portion 146 is the front-facing part of the seat back cushion 124. The upper portion 148 is the rear-facing part and is pivotably connected to the central portion 146 along the hinge 152. The lower portion 150 is also the rear-facing part and is pivotably connected to the central portion 146 along the hinge 154, which is separated from the upper hinge 152.

[0070] Figure 12 shows the rear side of cushion 124 in its extended orientation. The exposed rear surface is generally flat to facilitate the alignment of the surfaces of sections 146, 148, and 150. As shown in Figures 12 to 13, the lower section 150 is pivoted around hinge 154 and stacked flat on the rear surface of the central section 146. In Figures 13 to 14, the upper section 148 is pivoted around hinge 152 and stacked flat on the rear surface of the central section 146.

[0071] Next, parts 146, 148, and 150 can be fixed to each other by heat scribing, welding, adhesive, fasteners, surface fasteners, holders, etc. Figure 14 shows the rear view of the assembled seat back cushion 124. Collectively, the parts form grooves 156 for attachment to the seat back frame 158 (Figure 4). Figure 15 shows the front view of the assembled seat back cushion 124.

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

[0073] Figure 16 shows a cushion 160 according to another embodiment. Similar to the previous embodiment, the cushion 160 comprises a plurality of integrally formed and pivotably interconnected parts 162, 164, and 166. A fastening part 168 is provided along the joint between two of the parts 162 and 164. The fastening part 168 can be a heat-sealed part, a welded part, an adhesive, a hook-and-loop fastener, a retainer, etc.

[0074] Seat supports (e.g., 122, 124, and / or 136), which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas, and / or parts, are described. The seat supports (e.g., 122, 124, and / or 136) may be attached to a seat frame, wire suspension mat, substrate, and / or panel, which may be a stamped steel alloy, fiber-reinforced polymer, or any suitable structural material, and may support the occupant on the seat frame, and may be an extruded thermoplastic mesh, filament, three-dimensional filament rings of extruded foamed thermoplastic or polymer, multiple fusion joints where two rings are attached to each other, independently, 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3 The structure comprises multiple layers (e.g., 130, 132, 134, 138 and / or 140), sections, bases and / or bolsters, including a density of . The multiple layers (e.g., 130, 132, 134, 138 and / or 140) are stacked on top of each other and attached by retaining clips having ends embedded in the foam and retaining clip ends attached to the plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog rings, single-sided or double-sided retaining clips, joining, welding, sewing, fastening, bonding, heat riveting and / or holding.

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

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

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

[0078] In some embodiments, each of the multiple stacked layers (e.g., 162, 164, and / or 166) is pivotally connected to one another.

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

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

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

[0082] Seat supports (e.g., 122, 124, and / or 136), which may be seat base cushions, seat back cushions, headrests, head rests, bolsters, regions, and / or parts, are described. The seat supports (e.g., 122, 124, and / or 136) comprises multiple layers (e.g., 130, 132, 134, 138, and / or 140), parts, bases, and / or bolsters, which may be stamped steel alloys, fiber-reinforced polymers, or any preferred structural material, and are attached to a seat frame, wire suspension mat, base, and / or panel, to support the occupant on the seat frame. Multiple layers (e.g., 130, 132, 134, 138 and / or 140) are stacked on top of each other and can be attached by retaining clips having ends embedded in the foam and retaining clip ends attached to a plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog rings, single-sided or double-sided retaining clips, joining, welding, sewing, fastening, bonding, heat riveting and / or holding. At least one of the multiple stacked layers (e.g., 162, 164 and / or 166) has a generally uniform thickness, which may have a rectangular cross-section, consistent thickness and / or parallelogram shape. Each of the multiple stacked layers is formed integrally and / or as a single unit. Each of the multiple stacked layers (e.g., 162, 164 and / or 166) is pivotally connected to one another.

[0083] Figure 16B shows Method 1600 according to several embodiments. Method 1600 is for manufacturing cushions (e.g., cushions 122, 124, 130, 132, 134, 138 and / or 140) which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts. In various examples, Method 1600 may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0084] Method 1600 is described for manufacturing products which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts. Method 1600 may be an extruded thermoplastic mesh, a filament, a three-dimensional filament ring of an extruded foamed thermoplastic or polymer and / or a plurality of fused joints in which two rings are attached to each other, independently, 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3 The method includes forming a plurality of cushion portions (e.g., 130, 132, 134, 138 and / or 140) from an extruded thermoplastic resin mesh body having a density (1602), and stacking the plurality of cushion portions (e.g., 130, 132, 134, 138 and / or 140) as a cushion (e.g., cushions 122, 124 and / or 160) (1604).

[0085] In some embodiments, Method 1600 includes forming a plurality of cushion portions (e.g., 130, 132, 134, 138 and / or 140) which may be cutting, die-cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automated mechanical operations.

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

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

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

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

[0090] Seat supports, which may include a seat base cushion, a seat back cushion, a headrest, a head support, a bolster, an area, and / or a part, are described. The seat supports are manufactured from either of the techniques described above or subsequently.

[0091] In some embodiments, Method 1600 includes installing the product in a seat frame, wire suspension mat, substrate and / or panel, which may be a stamped steel alloy, fiber-reinforced polymer or any preferred structural material.

[0092] This document describes seat assemblies, which may include vehicle seats, office chairs, personal chairs, etc. The seat assemblies are manufactured by either of the techniques described above or described below.

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

[0094] Figure 16C shows Method 1650 according to several embodiments. Method 1650 is for manufacturing cushions (e.g., cushions 122, 124, 130, 132, 134, 138 and / or 140) which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts. In various examples, Method 1650 may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0095] Method 1650 is for designing seat cushions which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts. Method 1650 includes obtaining a design for a single seat cushion (e.g., a single seat cushion 122) (1652) and redesigning the single seat cushion design into a plurality of stacked cushion part designs (e.g., 130, 132 and / or 134), layers, parts, bases and / or bolsters (1654).

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

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

[0098] Figure 16D shows Method 1680 according to several embodiments. Method 1680 is for manufacturing seat cushions (e.g., cushions 122, 124, 130, 132, 134, 138 and / or 140), which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts. In various examples, Method 1680 may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0099] Method 1680 involves designing a plurality of cushion portion designs according to either the preceding or succeeding technique (1682), which can be an extruded thermoplastic mesh, a filament, a three-dimensional filament ring of extruded foamed thermoplastic or polymer, or a plurality of fusion joints formed by two rings adhering to each other, independently containing 60 to 95 volume percent of air, about 0.01 g / cm³. 3 ~0.200g / cm 3(1684) includes forming a plurality of cushion portions from an extruded thermoplastic resin mesh body containing the density of the above.

[0100] In some embodiments, method 1680 includes stacking a plurality of cushion portions as a cushion which may be a seat base cushion, a seat back cushion, a headrest, a head support, a bolster, an area and / or a portion.

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

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

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

[0104] Figures 19A and 19B show cross-sections of other modified forms of the vehicle seat cushion component 230. As described above, the vehicle seat cushion component 230 can be part of the vehicle seat backrest 212 or the vehicle seat bottom 214. The vehicle seat component 230 comprises a plastic mesh base 232. The plastic mesh base 232 has a first edge 234, a second edge 236, a first surface 238, and a second surface 240. The first plastic mesh bolster 242 is attached to the plastic mesh base 232 at the first edge 234. The second plastic mesh bolster 244 is attached to the plastic mesh base 232 at the second edge 236. The first plastic mesh bolster 242 comprises a first plurality of three-dimensional filament rings 250 made of a first thermoplastic polymer. The second plastic mesh bolster 244 comprises a second plurality of three-dimensional filament rings 252 made of a second thermoplastic polymer. The first plurality of three-dimensional filament rings 250 and the second plurality of three-dimensional filament rings 252 are each independently molded into a shape suitable for vehicle seat bolsters 242, 244. Dotted lines around these parts highlight the shape of these bolster parts. Similarly, the plastic mesh base 232 comprises a third plurality of three-dimensional filament rings 254 made of a third thermoplastic polymer. The third plurality of three-dimensional filament rings 254 are generally molded into a block shape or any shape suitable for functioning as a cushion. An optional surface layer 256 is placed on and in contact with the first surface 238 of the molded plurality of three-dimensional filament rings 254. The vehicle seat part 230 may comprise one or both of the surface layers 256 and 258.

[0105] Referring to Figures 18A, 18B, 19A, and 19B, the first plastic mesh bolster 242 is attached to the plastic mesh base 232, and the second plastic mesh bolster 244 is attached to the plastic mesh base 232. These attachment parts 260 and 262 can be any attachment mechanism known to those skilled in the art, such as Velcro® connecting strips (hook-shaped layer and ring-shaped layer), adhesive, hog rings, single-sided or double-sided retaining clips.

[0106] Methods for forming a first plurality of three-dimensional filament rings, a second plurality of three-dimensional filament rings, and a third plurality of three-dimensional filament rings, and examples of their properties, are disclosed in U.S. Patent No. 10,233,073 and U.S. Patent No. 9,918,559, and by reference thereto, the entirety of these disclosures is incorporated herein by reference.

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

[0108] In one modified form, the first plastic mesh bolster 242, the second plastic mesh bolster 244, and the plastic mesh base 232 independently contain 60 to 95 volume percent of air. In some improved forms, the first plastic mesh bolster 242, the second plastic mesh bolster 244, and the plastic mesh base 232 independently contain at least 60, 65, 70, 75, or 80 volume percent of air, in ascending order of preference, and at most 95, 93, 90, 85, or 80 volume percent of air, in ascending order of preference. In one improved form, the first plastic mesh bolster 242, the second plastic mesh bolster 244, and the plastic mesh base 232 independently contain about 0.01 g / cm³ 3 ~0.200g / cm 3 It has a density of . In some improved forms, the multiple three-dimensional filament rings include multiple fusion joints 264 where two rings are attached to each other.

[0109] In one modified form, the three-dimensional filament ring 250, three-dimensional filament ring 252, and three-dimensional filament ring 254, and any optional surface layer, if present, are independently composed of a thermoplastic polymer. In one improved form, the three-dimensional filament ring is an extruded thermoplastic polymer. Examples of thermoplastic polymers, but not limited to, include polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In one improved form, the thermoplastic polymer includes linear low-density polyethylene. In some improved forms, the three-dimensional filament ring has a fineness of 200 to 10,000 decitex. In one improved form, the three-dimensional filament ring has a fineness of 200 to 5,000 decitex. In a further improved form, the three-dimensional filament ring has a fineness of 200 to 3,000 decitex.

[0110] A vehicle seat cushion (e.g., vehicle seat cushion part 230) that can be a seat bottom cushion, a seat back cushion, a headrest, a head support, a bolster, a region and / or a portion is described. The vehicle seat cushion (e.g., vehicle seat cushion part 230) includes a first plastic mesh bolster (e.g., first plastic mesh bolster 242) formed by compression molding and including a first plurality of three-dimensional filament ring bodies (e.g., ring bodies 250). At least a subset of the ring bodies within the first plurality of three-dimensional filament ring bodies may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The first plurality of three-dimensional filament ring bodies are composed of a first thermoplastic polymer that can have a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3 and are each independently formed in the form of a vehicle seat bolster and can be a polyolefin, a styrene-based thermoplastic elastomer, a polyester-based thermoplastic elastomer, a polyurethane-based thermoplastic elastomer, a polyamide-based thermoplastic elastomer, and / or linear low-density polyethylene. The vehicle seat cushion (e.g., vehicle seat cushion part 230) includes a second plastic mesh bolster (e.g., second plastic mesh bolster 244) formed by compression molding and including a second plurality of three-dimensional filament ring bodies (e.g., ring bodies 252). At least a subset of the ring bodies within the second plurality of three-dimensional filament ring bodies may or may not be parallel to each other or aligned, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The second plurality of three-dimensional filament ring bodies are composed of a first thermoplastic polymer that can have a density of 60 volume percent to 95 volume percent air, about 0.01 g / cm 3 ~0.200 g / cm 3It is composed of a second thermoplastic polymer having a density of , each independently molded into the form of a vehicle seat bolster, and may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer and / or linear low-density polyethylene. The vehicle seat cushion (e.g., vehicle seat cushion component 230) comprises a plastic mesh base (e.g., plastic mesh base 232), the plastic mesh base may be an extruded thermoplastic resin mesh, a filament, a three-dimensional filament ring of extruded foamed thermoplastic resin or polymer, a plurality of fused connections where two rings are attached to each other, and independently contains 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3 The material contains a density of , and comprises a third plurality of three-dimensional filament rings (e.g., ring 254), where at least the partial aggregates of rings within the third plurality of three-dimensional filament rings may be parallel or aligned to each other, or not, and may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The third plurality of three-dimensional filament rings contain 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3It is composed of a third thermoplastic polymer having a density of , each independently molded into the form of a vehicle seat bolster, and may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer and / or linear low-density polyethylene. The plastic mesh base may have a block shape, and the plastic mesh base has a first edge (e.g., a first edge 234), a second edge (e.g., a second edge 236), a first face (e.g., a first face 238), and a second face (e.g., a second face 240). A first plastic mesh bolster (e.g., first plastic mesh bolster 242) is attached to a plastic mesh base (e.g., plastic mesh base 232) at a first edge (e.g., first edge 234), and a second plastic mesh bolster (e.g., second plastic mesh bolster 244) is attached to a plastic mesh base (e.g., plastic mesh base 232) at a first edge (e.g., first edge 234). The attachment may be by retaining clips having ends embedded in the foam and retaining clip ends attached to the plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog rings, single-sided or double-sided retaining clips, bonding, welding, sewing, fastening, adhesion, heat riveting and / or other means of retention.

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

[0112] In some embodiments, the first plurality of three-dimensional filament rings (e.g., ring 250), the second plurality of three-dimensional filament rings (e.g., ring 252), and the third plurality of three-dimensional filament rings each independently include a plurality of fusion splices formed by two rings being attached to each other.

[0113] In some embodiments, a first plurality of three-dimensional filament rings (e.g., ring 250) and a second plurality of three-dimensional filament rings (e.g., ring 252) are each independently molded into the form of a vehicle seat bolster.

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

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

[0116] In some embodiments, a first plastic mesh bolster (e.g., a first plastic mesh bolster 242) and a second plastic mesh bolster are attached to a plastic mesh base (e.g., a plastic mesh base 232) by face strips, adhesives, retaining clips and / or hog rings.

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

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

[0119] In some embodiments, the first surface layer is placed on the first surface of the plastic mesh base (e.g., the plastic mesh base 232).

[0120] In some embodiments, the first surface layer is placed on the second surface of the plastic mesh base (e.g., the plastic mesh base 232).

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

[0122] In some embodiments, the first plastic mesh bolster (e.g., the first plastic mesh bolster 242), the first plastic mesh bolster, and the plastic mesh base are independently approximately 0.01 g / cm³ 3 ~0.200g / cm 3 It has a density of .

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

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

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

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

[0127] Vehicle seat cushion components (e.g., 230) which may be seat bottom cushions, seat back cushions, headrests, head supports, bolsters, regions and / or parts are described. The vehicle seat cushion component (e.g., 230) comprises a first plastic mesh bolster (e.g., 242) which may be formed by compression molding and includes a first plurality of three-dimensional filament rings (e.g., 250), wherein at least partial aggregates of rings within the first plurality of three-dimensional filament rings may be parallel or aligned with each other, or not, or may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The first plurality of three-dimensional filament rings contain 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3 It is composed of a first thermoplastic polymer having a density of , each independently molded into the form of a vehicle seat bolster, and may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer and / or linear low-density polyethylene. A vehicle seat cushion component (e.g., 230) comprises a second plastic mesh bolster (e.g., 244) which can be formed by compression molding and includes a second plurality of three-dimensional filament rings (e.g., 252), wherein at least the partial aggregates of rings in the second plurality of three-dimensional filament rings may be parallel or aligned to each other, or not, or may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The second plurality of three-dimensional filament rings contain 60 to 95 volume percent of air, about 0.01 g / cm³3 ~0.200g / cm 3 It is composed of a second thermoplastic polymer having a density of , each independently molded into the form of a vehicle seat bolster, and may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer and / or linear low-density polyethylene. A vehicle seat cushion component (e.g., 230) comprises a plastic mesh base (e.g., 232), the plastic mesh base may be an extruded thermoplastic resin mesh, a filament, a three-dimensional filament ring of extruded foamed thermoplastic resin or polymer, a plurality of fused connections where two rings are attached to each other, and independently contains 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3 The material contains a density of , and comprises a third plurality of three-dimensional filament rings (e.g., 254), wherein at least the partial aggregates of rings within the third plurality of three-dimensional filament rings may be parallel or aligned to each other, or may be randomly oriented, and may have a fineness of 200 decitex to 10000 decitex. The third plurality of three-dimensional filament rings contain 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3It is composed of a third thermoplastic polymer having a density of , each independently molded into the form of a vehicle seat bolster, and may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer and / or linear low-density polyethylene. The plastic mesh base (e.g., 232) has a first edge, a second edge, a first face and a second face. The first plastic mesh bolster (e.g., 242) is attached to the plastic mesh base (e.g., 232) at the first edge, and the second plastic mesh bolster is attached to the plastic mesh base at the first edge. The attachment may be by retaining clips having ends embedded in a foam and retaining clip ends attached to a plastic mesh base, hook-shaped and ring-shaped connecting strips, hook-shaped layers, ring-shaped layers, adhesives, hog rings, single-sided or double-sided retaining clips, bonding, welding, sewing, fastening, adhesion, heat riveting and / or other means of retention. The first plurality of three-dimensional filament rings (e.g., 250), the second plurality of three-dimensional filament rings (e.g., 252), and the third plurality of three-dimensional filament rings (e.g., 254) each independently include a plurality of fusion connections in which two rings are attached to each other.

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

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

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

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

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

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

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

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

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

[0137] In one modified embodiment, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 are each independently composed of a foamed polymer. In one improved embodiment, the first core cushion portion 334 and the second core cushion portion 342 are each independently composed of foamed polyurethane. As is known in the art, foamed polyurethane is formed from the reaction of isocyanates, polyols, and preferred blowing agents.

[0138] In the alternative configurations shown in Figures 21A and 21B, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 are each independently composed of a plurality of three-dimensional filament rings or threads made of a thermoplastic polymer or resin. In one improved configuration, at least the partial aggregates of rings within the plurality of three-dimensional filament rings are not parallel to or aligned with each other. In one improved configuration, the rings within the plurality of three-dimensional filament rings are randomly oriented.

[0139] Referring further to Figures 21A and 21B, in another modified form, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 each independently include a plurality of three-dimensional filament rings having 60 to 95 volume percent of air. In some improved forms, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 each independently include a plurality of three-dimensional filament rings having at least 60, 65, 70, 75, or 80 volume percent of air, in ascending order of preference, and at most 95, 93, 90, 85, or 80 volume percent of air, in ascending order of preference. In one improved form, the first core cushion portion 334, the second core cushion portion 342, and the central cushion component 360 each independently contain approximately 0.01 g / cm³ 3 ~0.200g / cm 3 It includes a plurality of three-dimensional filament rings having a density of . In some improved forms, the plurality of three-dimensional filament rings include a plurality of fusion joints 364 in which two rings are attached to each other.

[0140] In one improved form, the three-dimensional filament ring is an extruded thermoplastic polymer. Examples of thermoplastic polymers include, but are not limited to, polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In one improved form, the thermoplastic polymer includes linear low-density polyethylene. In another improved form, the thermoplastic polymer is a biodegradable or recyclable polymer (e.g., a "green" polymer).

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

[0142] Methods for forming multiple three-dimensional filament rings and examples of their properties are disclosed in U.S. Patent No. 10,233,073 and U.S. Patent No. 9,918,559, and by reference thereto, the entirety of these disclosures is incorporated herein.

[0143] Advantageously, the aforementioned vehicle seat cushion component 330 improves the sustainability of current automotive seat components, provides support to the occupant, and improves the feel and damping quality (related to sound and energy) of extruded plastic mesh assemblies. In particular, the vehicle seat cushion component 330 provides sound dampening to a brittle mesh material that may generate some noise that may be added to the assembly, enables aggressive contouring and molding with respect to the A-side feature portion, and allows for multiple densities depending on the layer configuration (the top and bottom may have different densities depending on the temperature), thermal buffering (thermal insulation properties), and a consistent feel.

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

[0145] Vehicle seat cushion components (e.g., 330) which may be a seat base cushion, a seat back cushion, a headrest, a head support, a bolster, an area and / or part thereof are described. The vehicle seat cushion component (e.g., 330) is a first bolster assembly (e.g., 332) which may be formed by compression molding and comprises a first core cushion portion (e.g., 334), the first core cushion portion may be foamed polyurethane and is composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer, with 60 to 95 volume percent of air and about 0.01 g / cm³3 ~0.200g / cm 3 A first bolster assembly, comprising a first outer bolster cover (e.g., 336) having a density and being surrounded by a first bolster trim cover (e.g., 338) which can be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, and a second bolster assembly (e.g., 340) which can be formed by compression molding and comprises a second core cushion portion (e.g., 342), which may be foamed polyurethane and is composed of a plurality of three-dimensional filament rings made of thermoplastic polymer, with 60 to 95 volume percent air and about 0.01 g / cm³ 3 ~0.200g / cm 3 A second bolster assembly is surrounded by a second outer bolster cover (e.g., 344) having a density and which may be nonwoven fabric, natural fibers and / or jute fibers; and a trim cover portion (e.g., 350) is a trim cover portion which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material and has a first edge and a second edge, wherein the first bolster assembly (e.g., 332) is sewn to the trim cover portion (e.g., 350) at the first edge, and the second bolster assembly (e.g., 340) is sewn to the trim cover portion (e.g., 350) at the second edge.

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

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

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

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

[0150] In some embodiments, a vehicle seat cushion component (e.g., 330) further comprises a central cushion component (e.g., 360), the central cushion component may be foamed polyurethane and composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer, containing 60 to 95 volume percent air and / or about 0.01 g / cm³. 3 ~0.200g / cm 3 This is the density and can be positioned within the opening defined by the trim cover portion.

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

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

[0153] In some embodiments, the multiple three-dimensional filament rings include multiple fusion joints where two rings are attached to each other.

[0154] In some embodiments, at least a partial collection of rings within a plurality of three-dimensional filament rings is not parallel to or aligned with one another.

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

[0156] In some embodiments, the first core cushion portion (e.g., 334), the second core cushion portion (e.g., 342), and the central cushion portion (e.g., 360) each independently have a density of approximately 0.01 g / cm³. 3 ~0.200g / cm 3 It has a density of .

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

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

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

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

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

[0162] A vehicle seat (e.g., 310) is disclosed, which may be a vehicle seat, an office chair, a personal chair, etc. The vehicle seat (e.g., 310) comprises: a seat bottom having a seat bottom frame, wire suspension mat, base material and / or panel, which may be a stamped steel alloy, fiber-reinforced polymer or any suitable structural material; a seat back attached to the seat bottom having a seat back frame, wire suspension mat, base material and / or panel, which may be a stamped steel alloy, fiber-reinforced polymer or any suitable structural material; and a seat bottom cushion, seat back cushion, headrest attached to the seat bottom frame and / or seat back frame. The vehicle seat cushion component (e.g., 330) may be a stud, headrest, bolster, region and / or part, the vehicle seat cushion component (e.g., 330) may be formed by compression molding and comprises a first bolster assembly (e.g., 332) having a first core cushion portion (e.g., 334), the first core cushion portion may be foamed polyurethane and composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer, with 60 to 95 volume percent air and about 0.01 g / cm³ 3 ~0.200g / cm 3A first bolster assembly, comprising a first outer bolster cover (e.g., 336) having a density and being surrounded by a first bolster trim cover (e.g., 338) which can be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, and a second bolster assembly (e.g., 340) which can be formed by compression molding and comprises a second core cushion portion (e.g., 342), which may be foamed polyurethane and is composed of a plurality of three-dimensional filament rings made of thermoplastic polymer, with 60 to 95 volume percent air and about 0.01 g / cm³ 3 ~0.200g / cm 3 A second bolster assembly comprising: a second outer bolster cover (e.g., 344) having a density and being surrounded by a second bolster trim cover (e.g., 344) which may be nonwoven fabric, natural fibers and / or jute fibers, the second outer bolster cover being surrounded by a second bolster trim cover (e.g., 344) which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, and a trim cover portion having a first edge and a second edge, wherein the first bolster assembly (e.g., 332) is sewn to the trim cover portion at the first edge, and the second bolster assembly (e.g., 340) is sewn to the trim cover portion at the second edge.

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

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

[0165] In some embodiments, a vehicle seat cushion component (e.g., 330) further comprises a central cushion component (e.g., 360), the central cushion component may be foamed polyurethane and composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer, containing 60 to 95 volume percent air and / or about 0.01 g / cm³. 3 ~0.200g / cm 3 This is the density and can be positioned within the opening defined by the trim cover portion.

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

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

[0168] In some embodiments, the multiple three-dimensional filament rings include multiple fusion joints where two rings are attached to each other.

[0169] In some embodiments, at least a partial collection of rings within a plurality of three-dimensional filament rings is not parallel to or aligned with one another.

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

[0171] In some embodiments, the first core cushion portion (e.g., 334) and the second core cushion portion (e.g., 342) each independently have a density of approximately 0.01 g / cm³. 3 ~0.200g / cm 3 It has a density of .

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

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

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

[0175] Figures 23A and 23B show a cross-section of a vehicle seat component 430. Advantageously, the vehicle seat component 430 is the backrest or bottom of a vehicle seat. The vehicle seat component 430 comprises a plastic mesh base 432. The plastic mesh base 432 comprises a plurality 434 molded three-dimensional filament rings or threads made of a thermoplastic polymer or resin. In this regard, the plurality 434 three-dimensional filament rings generally have a block shape or any shape suitable for functioning as a cushion. The plastic mesh base 432 has a first edge 442, a second edge 444, a first face 446, and a second face 448. A first foam bolster 450 is attached to the plastic mesh base at the first edge 442. The second foam bolster 452 is attached to the plastic mesh base 432 at the second edge 444. Figure 23A shows an improved configuration in which the first foam bolster 450 is attached to the first edge 442 and the second foam bolster 452 is attached to the second edge 444, and Figure 23B shows an improved configuration in which the first foam bolster 450 and the second foam bolster 452 are each positioned on the first surface 446.

[0176] Figures 24A and 24B show cross-sections of other modified forms of the cushion portion of a vehicle seat. As described above, the vehicle seat component 430 is the backrest or bottom of the vehicle seat. The vehicle seat component 430 comprises a plastic mesh base 432. The plastic mesh base 432 comprises a plurality of molded three-dimensional filament rings 434 or threads made of a thermoplastic polymer or resin. The plastic mesh base 432 has a first edge 442, a second edge 444, a first surface 446 and a second surface 448. A first foam bolster 450 is attached to the plastic mesh base 432 at the first edge 442. A second foam bolster 452 is attached to the plastic mesh base 432 at the second edge 444. In this modified form, an optional skin layer 456 is positioned on and in contact with the first surface 446 of a plurality of molded three-dimensional filament rings 434. The optional skin layer 456 is positioned on and in contact with the first surface 446 of a plurality of molded three-dimensional filament rings 434. The vehicle seat component 430 may comprise one or both of the skin layers 456 and 458.

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

[0178] Referring to Figures 23A, 23B, 24A, and 24B, the first foam bolster 450 is attached to the plastic mesh base 432 by a first retaining clip 460, and the second foam bolster 452 is attached to the plastic mesh base 432 by a second retaining clip 462. The first retaining clip 460 and the second retaining clip 462 each independently have an end that is embedded in the foam and a retaining clip end that is attached to the plastic mesh base. An example of a retaining clip is disclosed in U.S. Patent Application No. 17 / 724,866, filed on April 20, 2022, and by reference thereto, the entirety of that disclosure is incorporated herein by reference.

[0179] Methods for forming multiple three-dimensional filament rings and examples of their properties are disclosed in U.S. Patent No. 10,233,073 and U.S. Patent No. 9,918,559, and by reference thereto, the entirety of these disclosures is incorporated herein.

[0180] Referring to Figures 23A, 23B, 24A, and 24B, at least a portion of the rings within the multiple three-dimensional filament rings are not parallel or aligned with each other. In one improved embodiment, the rings within the multiple three-dimensional filament rings are randomly oriented. The plastic mesh base is 60 to 95 volume percent air. In one improved embodiment, the plastic mesh base is approximately 0.01 g / cm³ 3 ~0.200g / cm 3 It has a density of . In some improved forms, the multiple three-dimensional filament rings include multiple fusion joints 464 where two rings are attached to each other.

[0181] In one modified form, the three-dimensional filament ring and, if present, an optional skin layer, are composed of a thermoplastic polymer. In one improved form, the three-dimensional filament ring is an extruded thermoplastic polymer. Examples of thermoplastic polymers, but not limited to, include polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. In one improved form, the thermoplastic polymer includes linear low-density polyethylene. In some improved forms, the three-dimensional filament ring has a fineness of 200 to 10,000 decitex. In one improved form, the three-dimensional filament ring has a fineness of 200 to 5,000 decitex. In a further improved form, the three-dimensional filament ring has a fineness of 200 to 3,000 decitex.

[0182] Vehicle seat cushion components (e.g., 430) which may be seat base cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts are described. Vehicle seat cushion components (e.g., 430) are plastic mesh bases (e.g., 432) which may be extruded thermoplastic meshes, filaments, three-dimensional filament rings of extruded foamed thermoplastic or polymer, multiple fused joints where two rings are attached to each other, independently containing 60 to 95 volume percent air, about 0.01 g / cm³ 3 ~0.200g / cm 3 The material comprises a plastic mesh base with a density of 432. The plastic mesh base (e.g., 432) comprises a plurality of three-dimensional filament rings, where at least a portion of the rings within the plurality of three-dimensional filament rings may be parallel or aligned to each other, or not, or may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex. The three-dimensional filament rings contain 60 to 95 volume percent air, about 0.01 g / cm³. 3 ~0.200g / cm 3The components are composed of thermoplastic polymers of a density such that each can be independently molded into the form of a vehicle seat bolster and may be polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, polyamide-based thermoplastic elastomers and / or linear low-density polyethylene. The plastic mesh base (e.g., 432) has a first edge, a second edge, a first surface which may be a surface layer and a second surface which may be a surface layer. The vehicle seat cushion component (e.g., 430) is a first foam bolster (e.g., 450) which may be a foam polymer, foam polyurethane, isocyanate, polyol and / or a suitable foaming agent, and may include retaining clips, hooks and rings having ends embedded in the foam and retaining clip ends attached to the plastic mesh base, connecting strips, hook layers, ring layers, adhesives, hog rings, single-sided or double-sided retaining clips, joining, welding, sewing, fastening The apparatus comprises a first foam bolster attached to a plastic mesh base (e.g., 432) at a first edge by adhesive, heat scribing and / or other means of holding, or otherwise, and a second foam bolster (e.g., 452) which may be a foamed polymer, foamed polyurethane, isocyanate, polyol and / or a suitable foaming agent, and which is attached to the plastic mesh base (e.g., 432) at a second edge.

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

[0184] In some embodiments, the plurality of three-dimensional filament rings include a plurality of fusion joints where two rings are attached to each other, and these joints may or may not be parallel or aligned to each other and / or may not be randomly oriented.

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

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

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

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

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

[0190] In some embodiments, at least a partial collection of rings within a plurality of three-dimensional filament rings is not parallel to or aligned with one another.

[0191] In some embodiments, the rings within a plurality of three-dimensional filament rings are randomly oriented.

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

[0193] In some embodiments, the plastic mesh base (e.g., 432) has a density of approximately 0.01 g / cm³. 3 ~0.200g / cm 3 It has a density of .

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

[0195] In some embodiments, the thermoplastic polymer comprises components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

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

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

[0198] Vehicle seat cushion components (e.g., 430) are disclosed, which may be a seat base cushion, a seat back cushion, a headrest, a head support, a bolster, an area and / or part. The vehicle seat cushion component is a plastic mesh base (e.g., 432), which may be an extruded thermoplastic mesh, a filament, a three-dimensional filament ring of an extruded foamed thermoplastic or polymer, a plurality of fused connections where two rings are attached to each other, independently containing 60 to 95 volume percent air, about 0.01 g / cm³ 3 ~0.200g / cm 3The material comprises a plastic mesh base (e.g., 432) with a density of 60 to 95 volume percent air, approximately 0.01 g / cm³ 3 ~0.200g / cm 3 It is composed of a thermoplastic polymer that can have a density of , each independently molded into the form of a vehicle seat bolster, and may be polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, polyamide-based thermoplastic elastomer and / or linear low-density polyethylene.

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

[0200] In some embodiments, the multiple three-dimensional filament rings include multiple fusion joints where two rings are attached to each other.

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

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

[0203] In some embodiments, the thermoplastic polymer comprises components selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

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

[0205] Figure 25 shows a seat assembly 520 according to one embodiment. The seat assembly 520 is shown as a vehicle seat that can be used as a seat assembly in land vehicles, aircraft, ships, etc. The seat assembly 520 can be used as an individual chair or bench chair in any row in a vehicle. Alternatively, the seat assembly 520 can also be used as an office chair or any other chair. The seat assembly 520 eliminates conventional foam in order to improve support and comfort. The seat assembly 520 can also optionally incorporate recycled materials that are manufactured for further recycling when the seat assembly 520 is no longer in use.

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

[0207] The seat base 522 may include a frame (not shown) for providing a rigid structural support to the seat base 522. Similarly, the seat back 524 may also include a frame (not shown) connected to the seat base frame, extending upright from the seat base 522 and providing a rigid structural support to the seat back 524. In some embodiments, a single (integrated) frame is optionally used for both the seat base 522 and the seat back 524 to provide a rigid structural support. These / this frames are optionally formed from a stamped steel alloy, fiber-reinforced polymer or any suitable structural material.

[0208] Conventional seat assemblies comprise multiple foam layers, collectively providing cushioning on the frame. These foam layers, varying in density, distribute forces from the occupant to the frame while providing flexible support to the occupant. The foam layers also provide comfort to the occupant. Furthermore, several non-foamed materials have been found to improve support, comfort, performance, and compactness, while also facilitating future recycling of the material at the end of the seat assembly's service life. Therefore, this disclosure relates to the use of non-foamed materials to provide cushioning on the frame.

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

[0210] Referring here to Figure 26, one of the seat base cushions 530 is partially shown detached from the seat assembly 520. The seat base cushion 530, which may, though not required, be the same as one or more seat back cushions 532, may be formed from a plurality of filaments 534 or rings of extruded foamed thermoplastic resin. In some embodiments, the seat base cushion 530 may also be optionally formed with or bonded to at least one layer (or membrane) 536 formed or bonded using the plurality of filaments 534. The layer 536 may be bonded to the plurality of filaments 534 by curing of the thermoplastic resin or by compression molding, adhesives, mechanical fasteners (e.g., clamps, hog rings, deflected and angled ribbed axial fasteners (also known as Christmas tree fasteners), hook-and-loop fasteners, etc.), sewing, or other bonding means. In some embodiments, the layer 536 may also be optionally extruded thermoplastic resin material, nonwoven material, or both. In one exemplary embodiment, the nonwoven material of layer 536 optionally includes jute, which is a biodegradable plant fiber.

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

[0212] In the illustrated embodiment, the hog ring 542 attached to the compression-molded jute 536 and the foamed thermoplastic resin mesh 534 provides sufficient attachment to withstand tension. For example, this embodiment can withstand tensile loads of at least 50 Newtons and up to 151 Newtons, with deformation of at least 26 mm and up to 44 mm.

[0213] Accordingly, a seat assembly comprising a seat base, a seat back and a seat trim assembly is disclosed herein, the seat trim assembly optionally located in the seat base, the seat back or both. The seat trim assembly disclosed herein optionally further comprises at least one fabric sized to be displaced across the surface of a cushion and at least one retainer coupled to the at least one fabric along the periphery of the fabric to receive a trim component. In some embodiments, the seat trim assembly optionally further comprises a cushion comprising a filamentous mesh material. Similarly, in some embodiments, the seat trim assembly further comprises a trim cover sized to at least partially enclose the cushion and at least one fabric sized so that the trim cover is coupled to at least one retainer. The at least one retainer may be coupled directly or indirectly to the cushion, trim component or trim cover.

[0214] The trim components of the seat trim assembly may be actuators such as air bladder assemblies, heat transfer layers such as heating mats, or any combination thereof. The retainers of the seat trim assembly may be one or more of at least one clamp ring, hog ring, Christmas tree fastener, hook-and-loop fastener, or any combination thereof. At least one fabric of the seat trim assembly may be any nonwoven material, fabric, textile, or any combination thereof. In some embodiments, the nonwoven material of at least one fabric may further include jute.

[0215] In some embodiments of the present disclosure, a seat assembly is disclosed comprising a seat base, a seat back, and a product formed by a method including the following steps, the product being located on the seat base, the seat back, or both. These steps optionally include joining at least one retainer to the periphery of at least one piece of fabric, stacking at least one piece of fabric onto a cushion, and joining trim components to at least one retainer. In some embodiments, the method further includes compression molding at least one piece of fabric to the contour of a cushion before stacking at least one piece of fabric onto the cushion. In other embodiments, at least one piece of fabric may be joined to the contour of the cushion via mechanical fasteners such as adhesives, clamps, hog rings, Christmas tree fasteners, hook-and-loop fasteners, etc., before stacking at least one piece of fabric onto the cushion. At least one retainer may be joined directly or indirectly to at least one retainer. In exemplary embodiments where at least one retainer is a clamp ring, another step of the method is clamping at least one clamp ring to the fabric. In some embodiments, stacking at least one fabric on top of the cushion optionally further includes stacking at least one fabric on top of a filamentous mesh material cushion.

[0216] In some embodiments, the product formed by the method described above further includes connecting a trim cover, dimensioned to at least partially enclose the cushion and at least one fabric, to at least one retainer. In some exemplary embodiments, the trim component of the product formed by this method may be an actuator such as an air bag assembly, a heat transfer layer such as a heating mat, or any combination thereof. The retainer of the product formed by this method may be at least one clamp ring, hog ring, Christmas tree fastener, hook-and-loop fastener, or any combination thereof. The at least one fabric of the product formed by this method may be any nonwoven material, fabric, textile, or any combination thereof. In some exemplary embodiments, the nonwoven material of at least one fabric further includes jute.

[0217] In other aspects of the present disclosure, a trim assembly manufactured by the following method is disclosed. This method includes coupling at least one retainer to the periphery of at least one fabric, stacking at least one fabric on a cushion, and coupling trim components such as actuators, heat transfer layers, or any combination thereof to at least one retainer. In some embodiments, the method optionally further includes coupling a trim cover to at least one retainer to at least partially enclose the cushion and at least one fabric. The at least one retainer, which may be directly or indirectly coupled to at least one fabric, cushion, or trim component, is optionally one or more of at least one clamp ring, hog ring, Christmas tree fastener, hook-and-loop fastener, or any combination thereof. The at least one fabric of the trim assembly manufactured by the method described above may be any nonwoven material, fabric, textile, or any combination thereof. In some embodiments, the nonwoven material of at least one fabric further includes jute.

[0218] An assembly (e.g., seat assembly 520) which may be a vehicle seat, office chair, personal chair, etc. is described. The assembly (e.g., 520) includes at least one fabric which may be a nonwoven material, biodegradable plant fiber, jute and / or extruded thermoplastic material. The at least one fabric is sized to be displaced across the surface of a cushion (e.g., 530 and / or 532), which may be a filamentous mesh material, annular extruded foamed thermoplastic resin, extruded thermoplastic resin mesh, filamentous material, three-dimensional filament annular extruded foamed thermoplastic resin or polymer, multiple fused joints where two annulars are attached to each other, independently containing 60 to 95 volume percent air, about 0.01 g / cm³ 3 ~0.200g / cm 3 The density includes. At least one retainer (e.g., 542) can receive trim parts (e.g., 538 and / 540) which may be clamp rings, hog rings, deflected and angled ribbed axial fasteners, hook and loop fasteners, sewn, glued, welded, crimped, connecting strips, retaining clips, clamps, return fasteners, laminated and / or compression molded to at least one fabric along the periphery of the fabric and not directly bonded to the cushion, one or more panels of trim covers, nonwoven materials, biodegradable plant fibers, jute, extruded thermoplastic materials, fabrics, leather, synthetic leather, vinyl and / or other materials, actuators (e.g., 538 and / 540) such as air bag assemblies, heat transfer layers (e.g., 538 and / 540) such as heating mats or any combination thereof.

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

[0220] In some embodiments, the cushions (e.g., 530 and / or 532) can be extruded thermoplastic resin meshes, filaments, three-dimensional filament rings of extruded foamed thermoplastic resin or polymer, or multiple fused connections where two rings are attached to each other, and independently contain 60 to 95 volume percent of air, about 0.01 g / cm³ 3~0.200g / cm 3 The material further comprises a filamentous mesh-like material having a density such that at least the partial aggregates of rings within a plurality of three-dimensional filament rings may be parallel or aligned to each other, or not, or may be randomly oriented, and may have a fineness of 200 decitex to 10,000 decitex.

[0221] In some embodiments, the assembly comprises a trim cover which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, dimensioned to at least partially enclose the cushion (e.g., 530 and / or 532) and at least one fabric, the trim cover being coupled to at least one retainer.

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

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

[0224] In some embodiments, at least one fabric further comprises a nonwoven material.

[0225] In some embodiments, the nonwoven material further includes jute.

[0226] A seat assembly, which may be a vehicle seat, office chair, personal chair, etc., is described. The seat assembly comprises a seat base, a seat back, and a seat trim assembly located on the seat base or seat back. The seat trim assembly may be one or more panels of a trim cover, nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl, and / or other material.

[0227] Products that may be seat bottom cushions, seat back cushions, headrests, head supports, bolsters, areas and / or parts are described. The products may consist of at least one retainer (e.g., 542) that is not directly bonded to the cushion, which may be a clamp ring, hog ring, deflected and angled ribbed axial fastener, hook and loop fastener, sewing, adhesive, welding, crimping, connecting strip, retaining clip, clamp, return fastener, lamination and / or compression molding, bonded to the periphery of at least one fabric which may be a nonwoven material, biodegradable plant fiber, jute and / or extruded thermoplastic resin material, and may consist of filamentous mesh material, rings of extruded foamed thermoplastic resin, extruded thermoplastic resin mesh, filaments, three-dimensional filament rings of extruded foamed thermoplastic resin or polymer, and multiple fusion joints in which two rings are attached to each other, independently containing 60 to 95 volume percent air, about 0.01 g / cm³ 3 ~0.200g / cm 3 Formed by a method comprising stacking at least one fabric on a cushion (e.g., 530 and / or 532) having a density of , and attaching at least one trim part, which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, an actuator, which may be an air bag assembly, a heat transfer layer, which may be a heating mat, or any combination thereof, to at least one retainer (e.g., 542) (by or without means of retainers, clamp rings, hog rings, deflected and angled ribbed axial fasteners, hook and loop fasteners, sewing, adhesive, welding, crimping, connecting strips, retaining clips, clamps, return fasteners, lamination and / or compression molding, or by means of retainers, clamp rings, hog rings, deflected and angled ribbed axial fasteners, hook and loop fasteners, sewing, adhesive, welding, crimping, connecting strips, retaining clips, clamps, return fasteners, lamination and / or compression molding, or otherwise).

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

[0229] In some embodiments, the method further includes coupling a trim cover, which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material (by or without means of fixing a cushion, clamp ring, hog ring, deflected and angled ribbed axial fastener, hook and loop fastener, sewing, adhesive, weld, crimp, connecting strip, retaining clip, clamp, return fastener, lamination and / or compression molding) to at least one retainer (e.g., 542), which is sized to at least partially surround a cushion (e.g., 530 and / or 532) and at least one fabric.

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

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

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

[0233] A seat assembly, which may be a vehicle seat, office chair, personal chair, etc., is described. The seat assembly comprises a seat base, a seat back, and a product located on the seat base or seat back, which is made by one of the techniques described above or below.

[0234] Figure 27B shows Method 2700 according to several embodiments. Method 2700 is for bonding retainers (e.g., 542) that are not directly bonded to a cushion, such as clamp rings, hog rings, deflected and angled ribbed axial fasteners, hook and loop fasteners, stitching, adhesives, welds, rivets, connecting strips, retaining clips, clamps, return fasteners, laminations and / or compression molded materials, to a fabric which may be a nonwoven material, a biodegradable plant fiber, jute and / or an extruded thermoplastic material. In various examples, Method 2700 may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0235] Method 2700 includes bonding at least one retainer (e.g., 542) (by or without means of retainers, clamp rings not directly bonded to cushions, hog rings, deflected and angled ribbed axial fasteners, hook and loop fasteners, sewing, adhesives, welds, riveting, connecting strips, retaining clips, clamps, return fasteners, lamination and / or compression molding) to the periphery of at least one fabric which may be a nonwoven material, biodegradable plant fiber, jute and / or extruded thermoplastic material (2702). Method 2700 may be a filamentous mesh material, annular extruded foamed thermoplastic resin, extruded thermoplastic resin mesh, filament, three-dimensional filament annular extruded foamed thermoplastic resin or polymer, a plurality of fused joints in which two annulars are attached to each other, independently, 60 to 95 volume percent of air, about 0.01 g / cm³ 3 ~0.200g / cm 3 Method 2700 includes stacking at least one fabric on a cushion (e.g., 530 and / or 532) having a density of (2704). Method 2700 includes coupling at least one retainer (e.g., 542) to a trim component which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, an actuator which may be an air bag assembly, a heat transfer layer which may be a heating mat, or any combination thereof.

[0236] In some embodiments, Method 2700 includes at least partially surrounding a cushion (e.g., 530 and / or 532) and at least one piece of fabric by attaching a trim cover, which may be one or more panels of nonwoven material, biodegradable plant fiber, jute, extruded thermoplastic material, fabric, leather, synthetic leather, vinyl and / or other material, to at least one retainer (e.g., 542).

[0237] In some embodiments, at least one fabric further comprises a nonwoven material.

[0238] A trim assembly is described which may be one or more panels of nonwoven materials, biodegradable plant fibers, jute, extruded thermoplastic materials, fabrics, leather, synthetic leather, vinyl, and / or other materials. The trim assembly is manufactured by either of the techniques described above or subsequently.

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

[0240] Referring to Figure 28, a seat assembly 620 such as a vehicle seat assembly 620 is shown. In other examples, the seat assembly 620 may be molded and sized as a front-row driver's or passenger's seat, a second-row, third-row, or other rear-row seat, and may include bench-style seats, bucket seats, or other seat styles as shown. Furthermore, the seat assembly 620 may be a non-storable seat or a storable seat that is foldable and can be stored in a cavity in the vehicle floor. In addition, the seat assembly 620 may be configured for use in other non-vehicle applications.

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

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

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

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

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

[0246] In one non-limiting example, a non-foamed component, i.e., member 642, of the seat cushion 640 is formed from a filamentous mesh material, also known as an entangled three-dimensional filament structure. The filamentous mesh material is made from a polymer mesh having a plurality of integrated polymer filaments. The filamentous mesh material may be made from, for example, linear low-density polyethylene (LLDPE) material, but other polymers and materials effective in providing desired properties and functionality are also intended. The filamentous mesh material can be formed using extruded linear low-density polyethylene (LLDPE) filaments that are randomly entangled, bent, ring-shaped or otherwise positioned and oriented and directly joined to each other to provide a porous mesh structure, an example of which is shown in an enlarged view of Figure 29.

[0247] Referring to Figures 28, 33, and 37, various embodiments of the member 642 are shown. The member 642 may be used as a cushion for a seat assembly such as a vehicle seat assembly 620, or for other non-vehicle or non-seat applications. The member 642 of the cushion 640 may be formed from a filamentous mesh material as a single integral part from a single extrusion, for example, as described below, or it may be formed from the filamentous mesh material alone. Furthermore, the filamentous mesh material may include a polymer mesh having a plurality of integrated polymer filaments as described above.

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

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

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

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

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

[0253] In one example, each groove 662 has a first surface 664 and a second surface 672, and the groove 662 can be formed to have a V-shape, U-shape or other cross-sectional shape when the member is in a first position. A V-shaped groove 662 is shown by one non-limiting example. The first surface 664 and the second surface 672 fit together, contact each other, or move toward each other in any other way when the member 642 is in a second position as shown in Figure 37.

[0254] The first surface 664 and the second surface 672 may be connected to each other to hold the member 642 in a second position, as shown in Figure 37. In one example, one or more grooved fasteners 668 are provided to connect the first surface 664 to the second surface 672 and to hold the member 642 in a second position. The grooved fasteners 668 may be provided by hog rings, hook and loop fasteners, barbed fasteners, clips, etc. In another example, the first surface 664 and the second surface 672 may be joined to each other, for example, via adhesive or by lamination or welding by melting filamentous material on one surface to filamentous material on the other surface.

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

[0256] In various examples, the cushion 640 also comprises one or more secondary members 648 supported by member 642, as shown in Figures 28 and 34. These secondary members 648 may be provided from separate extrusion molding of filamentous mesh material, other non-foaming material, foam such as molded polyurethane foam, or a combination thereof. The secondary members 648 may extend outward from a first surface 654 and / or a second surface 656 of member 642, or from a first end region 650 and / or a second end region 652. In one example, the secondary members 648 may form elements of the cushion 640, such as a side bolster or a lumbar support pad or bolster.

[0257] The secondary member 648 can be connected to the member 642 to form the cushion 640. In one example, one or more secondary fasteners 670 are provided to connect the secondary member 648 to the member 642. The secondary fasteners 670 may be provided by hog rings, hook and loop fasteners, barbed fasteners, clips, etc. In another example, the secondary member 648 may be joined to the member 642, for example, via adhesive or by lamination or welding by melting filamentous material on one surface to filamentous material on the other surface.

[0258] Although the secondary member 648 is shown only in relation to Figures 28 and 34, it is also conceivable that the secondary member may be attached by member 642 in Figure 37 or otherwise supported.

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

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

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

[0262] The die plate 730 extrudes the material into a filament 740. The die plate 730 may be configured as described below, depending on the direction of extrusion to the final member 642 produced therefrom. More specifically, the die plate 730 has a number of small circular through-holes or openings through which the molten material passes. A single filament 740 is extruded from each die plate hole. The filament 740 falls downward from the die plate into the funnel 750 under system pressure and gravity, as described below. The funnel 750 may have the same or a different cross-sectional shape as the shape collectively defined by the openings of the die plate.

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

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

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

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

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

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

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

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

[0271] With respect to the resulting connected filament structure 760, the structure is cut such that the cut portion forms a first surface 654 or a second surface 656 as described above, and member 642 retains an outer peripheral shape as indicated by the die and / or funnel pattern / periphery 802. Furthermore, if the connected filament structure 760 is cut across a page, for example, referring to Figure 31, the side surface 658 of the resulting member 642 is formed by the extruded connected filament structure 760. Thus, the thickness of member 642 or the length of the side surface 658 is determined by where the connected filament structure 760 is cut.

[0272] Figure 35 shows a top view of a tool 820, such as a die 730 and / or funnel 750, for use with a manufacturing process 700 according to another embodiment of Figure 30. Figure 36 shows a schematic side view of a filamentous mesh material member 642 in a first configuration or position, as provided by the tool 820 of Figure 31. Note that the resulting member 642 can be seen in Figure 28 as a perspective view in a second position, according to one non-limiting example.

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

[0274] With respect to the resulting connected filament structure 760, the structure is cut such that the cut portion forms the side surface 658 as described above, and member 642 retains a cross-sectional shape as indicated by the die pattern and / or funnel shape 822. Furthermore, if the connected filament structure 760 is cut across the plane of the paper, for example with reference to Figure 35, the first surface 654 and second surface 656 of the resulting member 642 are formed by the extruded connected filament structure, for example by the edges 826, 828 of the die 730. Thus, the width of member 642 or the distance between the opposing left and right side surfaces 658 of member 642 is determined by where the connected filament structure 760 is cut.

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

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

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

[0278] Furthermore, one or more grooves 662 may be formed during at least one of the following processes: extruding the material, pouring the extruded material, and moving the extruded material. Alternatively, the grooves 662 may be formed within the member 642 after the connecting filament structure 760 has been cut to form the member.

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

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

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

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

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

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

[0285] The terms seat assembly, seat, or chair may be used herein to generally refer to an assembly incorporating teachings of one or more embodiments disclosed herein, which may include any combination of embodiments or features of embodiments disclosed herein. Similarly, the terms seat assembly, seat, or chair may refer to the same or similar assembly. Seat base, back, base, headrest, headrest, or bolster may be used herein to generally refer to any part, area, or portion of a seat assembly, vehicle seat, or chair. Layer, sheet, substrate, portion, area, or portion may refer to any planar, non-planar, molded, or contoured portion or area of ​​a seat base, back, base, headrest, headrest, or bolster that is formed from any disclosed material or combination of materials and provides comfort and / or structure to the seat base, back, base, headrest, headrest, or bolster. Joining, connecting, welding, sewing, fastening, holding, bonding, attaching, joining or crimping can refer to any manufacturing method or process for connecting parts by or without means of fasteners, retainers, adhesives, welds, hog rings, connecting strips, retaining clips, hook-and-loop fasteners, clamps, ribbed axial fasteners with angled flexures, return fasteners, lamination, compression molding, or additional trim parts. Filaments, threads, bends, or rings can be used herein to refer to generally linear polymer units after they have been extruded through one or more orifices of dies, plates, die plates, tools, tool plates, extrusion dies, or breaker plates or other variations thereof, which are similarly used to refer to parts of the same nature (however, they can be ring-shaped together to form a mesh-like structure, fused together, or joined). Similarly, linked filament structures, filament structures, entangled filament structures, yielded strands, main body, mesh structure, final member, non-foamed part, nonwoven mesh structure, non-foamed material, support, part, core, member, extruded material, cushioning material, cushion, or cushioning part may refer to the same or similar part. The terms funnel and cover may also be used to refer to the same or similar part.The descriptions herein may also use various terms to refer to holes, orifices, nozzles, openings, and other similar components. In yet another example, tank, water tank, cooling chamber, liquid tank, and vessel may refer to the same or similar component. The use of different terms to refer to the same or similar component may be used to avoid confusion when describing different preferred embodiments. These terms may be interchangeable, since various components of features from different embodiments may be combined in ways not expressly described herein. This does not impair the fact that, unless otherwise specified, certain terms may provide unique details not included in other interchangeable terms (for example, water tank and liquid tank refer to similar interchangeable components, but in at least one preferred embodiment, the tank is filled with water, or arranged to be filled with water, rather than any liquid, when a water tank is used).

[0286] A cushion (e.g., 640) which may be a seat base cushion, a seat back cushion, a headrest, a head support, a bolster, a region, or a portion is described. The cushion (e.g., 640) comprises a member (e.g., 642) which may be a foam, a non-foam, and / or a combination thereof. The member (e.g., 642) may be a plurality of integrated polymer filaments, an entangled three-dimensional filament structure, a linear low-density polyethylene, a polymer network having extruded filaments, and includes a filamentous network material which is randomly entangled, bent, ring-shaped, or otherwise positioned and oriented and / or directly joined to one another to provide a porous network structure. The member (e.g., 642) defines a first end region (e.g., 650) which may be molded to define a seat back cushion and a second end region (e.g., 652) which may be molded to define a seat base cushion. A first end region (e.g., 650) and a second end region (e.g., 652) are bounded by the outer circumference of the member (e.g., 642). The first end region (e.g., 650) is positioned (bent, folded, curved, and / or oriented) at a non-zero angle (e.g., 90 to 120 degrees or 90 to 150 degrees) relative to the second end region (e.g., 652).

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

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

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

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

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

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

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

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

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

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

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

[0298] In some embodiments, the cushion (e.g., 640) further comprises one or more secondary member (e.g., 648) fastenings, which may be hog rings, hook-and-loop fasteners, return fasteners, clips, adhesives, laminations and / or welds, connecting the secondary member (e.g., 648) to the member (e.g., 642).

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

[0300] A seat assembly is described which may be a vehicle seat, an office chair, and / or a personal chair. The seat assembly comprises a frame, a wire suspension mat, a base material, and / or panels which may be a stamped steel alloy, a fiber-reinforced polymer, and / or any suitable structural material, and a cushion (e.g., 640) made by any of the above or subsequent techniques. The cushion (e.g., 640) is supported by the frame.

[0301] A tool is described. The tool comprises a die (e.g., 730) (or funnel) that defines a series of openings, which are arranged to extrude material for a filamentous mesh material member for a cushion (e.g., 640) by either of the techniques described above or subsequently. The series of openings are arranged to define the outer periphery of a member (e.g., 642) including a seat back region and a seat base region.

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

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

[0304] Figure 38 shows Method 3800 according to several embodiments. Method 3800 may be a polymer network having multiple integrated polymer filaments, entangled three-dimensional filament structures, linear low-density polyethylene, or extruded filaments, and is for positioning filamentous network material members (e.g., bent, folded, curved, and / or oriented) that are randomly entangled, bent, ring-shaped, or otherwise positioned and oriented and / or directly joined to each other to provide a porous network structure. In various examples, Method 3800 may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially or simultaneously.

[0305] Method 3800 provides a porous mesh structure by which a polymer mesh material member (e.g., 642) can be molded to define a seat back cushion, and a first end region (e.g., 650) of the member (e.g., The method includes positioning the first end region (e.g., 650) at a non-zero angle (e.g., 90 to 120 degrees and / or 90 to 150 degrees) relative to the second end region (e.g., 652) of 642) (3802) (e.g., bending, folding, curving and / or oriented), and holding the first end region (e.g., 650) at a non-zero angle relative to the second end region (e.g., 652) by or without means of hog rings, hook and loop fasteners, barbed fasteners, clips, adhesives, laminations and / or welds (3804).

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

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

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

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

[0310] In some embodiments, Method 3800 includes forming one or more grooves (which may be by extrusion, die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automated mechanical operations) during at least one of extruding a material, pouring an extruded material, and moving an extruded material.

[0311] In some embodiments, Method 3800 includes cutting one or more grooves into a member (e.g., 642) (which may be by die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automated mechanical operations).

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

[0313] In some embodiments, method 3800 includes cutting an extruded material to form the outer surface of a member (e.g., 642) (which may be by die cutting, robotic laser cutting, waterjet cutting, laser cutting and / or other flexible automated mechanical operation), the outer surface extending over a first end region (e.g., 650) and a second end region (e.g., 652).

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

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

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

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

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

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

[0320] Item 1. A seat support, in combination with or not in combination with any of the following items, comprising multiple flat layers, which are attached to a seat frame and support a passenger on the seat frame, wherein the multiple flat layers are stacked on top of each other, and each of the multiple stacked layers has a different density.

[0321] Item 2. A seat support according to either the preceding or succeeding item, wherein multiple stacked layers differ in density such that the density increases continuously from the passenger support surface to the base layer.

[0322] Item 3. A seat support according to either of the preceding or succeeding items, wherein multiple stacked layers differ in stiffness such that the stiffness increases continuously from the passenger support surface to the base layer.

[0323] Item 4. Multiple stacked layers, together connected, are seat supports as described in either the preceding or succeeding item.

[0324] Item 5. Each consecutive pair of multiple stacked layers is joined together with the seat support described in either the preceding or succeeding item.

[0325] Item 6. Each consecutive pair of multiple stacked layers is welded, sewn, fastened or bonded together to the seat support described in either the preceding or succeeding item.

[0326] Item 7. A seat support according to either of the preceding or following items, wherein the multiple stacked layers further comprise rubber, carpet, needle-punched cotton regenerated wool, polyethylene terephthalate, or polypropylene.

[0327] Item 8. A seat support according to either of the preceding or following items, wherein the multiple stacked layers further include a base layer adapted for attachment to a seat frame, the base layer being formed from a material of higher density than the other layers of the multiple stacked layers.

[0328] Item 9. The base layer is formed from an elastomer material, and is a seat support according to either of the preceding or following items.

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

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

[0331] Item 12. A seat assembly comprising a base material adapted to be attached to a seat frame, and a seat support described in either the preceding or succeeding item, which is stacked on the base material.

[0332] Item 13. The base material is formed from an elastomer material, as described in either the preceding or following item.

[0333] Item 14. A seat assembly according to either of the preceding or following items, wherein the base material is formed from ethylene propylene diene monomer rubber, thermoplastic polyurethane, or foamed polyvinyl chloride.

[0334] Item 15. A seat assembly according to either the preceding or following item, further comprising a seat frame, wherein the base material is attached to the seat frame.

[0335] Item 16. A seat support, in combination with or uncombined with either a preceding or succeeding item, comprising multiple flat layers attached to a seat frame and supporting a passenger on the seat frame, wherein the multiple flat layers are stacked on top of each other, and the multiple stacked layers differ in density such that the density increases continuously from the passenger support surface to the base layer.

[0336] Item 17. A method for manufacturing a seat assembly, which includes unwinding a first sheet of a first material, cutting a first seat support layer from the first sheet, placing the first seat support layer on a substrate, unwinding a second sheet of a second material having a density lower than that of the first material, cutting a second seat support layer from the second sheet, and placing the second seat support layer on the first seat support layer, in combination with or without any of the preceding or succeeding items.

[0337] Item 18. The method of either the preceding or following item, further comprising unwinding a third sheet of a third material having a density lower than that of a second material, cutting a third seat support layer from the third sheet, and placing the third seat support layer on top of the second seat support layer.

[0338] Item 19. The method of either the preceding or succeeding item, further comprising joining a second seat support layer to a first seat support layer.

[0339] Item 20. A seat assembly manufactured from the method described in either the preceding or succeeding item.

[0340] Item 21. A seat support, combined with or uncombined with either the preceding or succeeding item, comprising multiple layers of extruded thermoplastic mesh material, which are attached to a seat frame and support a passenger on the seat frame, with the multiple layers stacked on top of each other.

[0341] Item 22. A seat support according to either of the preceding or succeeding items, wherein at least one of the multiple stacked layers has a generally uniform thickness.

[0342] Item 23. A seat support according to either of the preceding or succeeding items, wherein each of the multiple stacked layers has a generally uniform thickness.

[0343] Item 24. A seat support according to either of the preceding or succeeding items, further comprising at least two stacked layers.

[0344] Item 25. A seat support described in either the preceding or succeeding item, wherein each of the multiple stacked layers is pivotably connected to one another.

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

[0346] Item 27. Each of the multiple stacked layers is integrally formed, a seat support as described in either the preceding or succeeding item.

[0347] Item 28. A seat assembly comprising a seat frame and a seat support attached to the seat frame, as described in either the preceding or succeeding item.

[0348] Item 29. A seat support, combined with or uncombined with either a preceding or succeeding item, which is attached to a seat frame and supports a passenger on the seat frame, comprising multiple layers stacked on top of each other, at least one of the stacked layers having a generally uniform thickness, each of the stacked layers being integrally formed, and each of the stacked layers being pivotably connected to each other.

[0349] Item 30. A method for manufacturing a product, in combination with or without any of the preceding or succeeding items, which includes forming multiple cushion portions from an extruded thermoplastic resin mesh and stacking multiple cushion portions as a cushion.

[0350] Item 31. The method of either the preceding or succeeding item, further comprising molding multiple cushion portions.

[0351] Item 32. The method of either the preceding or succeeding item, further comprising forming multiple cushion portions as a single sheet.

[0352] Item 33. The method of either the preceding or following item, further comprising folding the cushion portions so that they are stacked on top of each other.

[0353] Item 34. The method of either the preceding or succeeding item, further comprising forming at least one recess in at least one of a plurality of cushion portions in order to fold the cushion portion.

[0354] Item 35. A method of either the preceding or succeeding item, further comprising cutting multiple cushion portions in order to form multiple cushion portions.

[0355] Item 36. A seat support manufactured from either a preceding or succeeding item.

[0356] Item 37. A method of either the preceding or succeeding item, further comprising installing the product into a seat frame.

[0357] Item 38. A seat assembly manufactured by the method described in either the preceding or succeeding item.

[0358] Item 39. A method for designing a seat cushion in combination with or without a preceding or succeeding item, comprising obtaining a design for a single seat cushion and redesigning the single seat cushion design into a plurality of stacked cushion portion designs.

[0359] Item 40. The method of either the preceding or succeeding item, further comprising redesigning a single-piece seat cushion design into a plurality of stacked cushion portion designs, each having a common maximum thickness.

[0360] Item 41. A method for manufacturing a seat cushion, comprising designing a plurality of cushion portion designs described in either a preceding or succeeding item, and forming the plurality of cushion portions from an extruded thermoplastic mesh.

[0361] Item 42. A method of either the preceding or succeeding item, further comprising stacking multiple cushion portions as cushions.

[0362] Item 43. A vehicle seat cushion component, in combination with or not in combination with either of the preceding or succeeding items, comprising: a first plastic mesh bolster comprising a first plurality of three-dimensional filament rings made of a first thermoplastic polymer; a second plastic mesh bolster comprising a second plurality of three-dimensional filament rings made of a second thermoplastic polymer; and a plastic mesh base comprising a third plurality of three-dimensional filament rings made of a third thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first face, and a second face, the first plastic mesh bolster being attached to the plastic mesh base at the first edge, and the second plastic mesh bolster being attached to the plastic mesh base at the first edge.

[0363] Item 44. Vehicle seat cushion components are vehicle seat cushion components included in the back of a vehicle seat or the bottom of a vehicle seat, as described in either the preceding or following item.

[0364] Item 45. A vehicle seat cushion component according to either of the preceding or following items, wherein the first plurality of three-dimensional filament rings, the second plurality of three-dimensional filament rings, and the third plurality of three-dimensional filament rings each independently include a plurality of fusion joints in which two rings are attached to each other.

[0365] Item 46. A vehicle seat cushion component according to either of the preceding or following items, wherein the first plurality of three-dimensional filament rings and the second plurality of three-dimensional filament rings are each independently molded into a form for a vehicle seat bolster.

[0366] Item 47. The first plastic mesh bolster and the second plastic mesh bolster are vehicle seat cushion components described in either the preceding or following item, each positioned on the first surface.

[0367] Item 48. A vehicle seat cushion component according to either of the preceding or following items, wherein a first plastic mesh bolster is attached to a first edge and a second plastic mesh bolster is attached to a second edge.

[0368] Item 49. A vehicle seat cushion component as described in either of the preceding or following items, wherein the first plastic mesh bolster and the second plastic mesh bolster are attached to the plastic mesh base by face strips, adhesive, retaining clips and / or hog rings.

[0369] Item 50. A vehicle seat cushion component according to either of the preceding or following items, wherein at least a portion of the rings in a first plurality of three-dimensional filament rings, at least a portion of the rings in a second plurality of three-dimensional filament rings, and at least a portion of the rings in a third plurality of three-dimensional filament rings are not parallel to or aligned with each other.

[0370] Item 51. A vehicle seat cushion component according to either of the preceding or following items, wherein at least a portion of the rings in a first plurality of three-dimensional filament rings, at least a portion of the rings in a second plurality of three-dimensional filament rings, and at least a portion of the rings in a third plurality of three-dimensional filament rings are randomly oriented.

[0371] Item 52. A vehicle seat cushion component according to either of the preceding or following items, wherein the first surface layer is disposed on the first surface of the plastic mesh base.

[0372] Item 53. A vehicle seat cushion component according to either of the preceding or following items, wherein the first surface layer is disposed on the second surface of the plastic mesh base.

[0373] Item 54. The first plastic mesh bolster, the first plastic mesh bolster and the plastic mesh base, independently containing 60 to 95 volume percent of air, are vehicle seat cushion components as described in either the preceding or following item.

[0374] Item 55. The first plastic mesh bolster, the second plastic mesh bolster, and the plastic mesh base each independently contain approximately 0.01 g / cm³ of material. 3 ~0.200g / cm 3 A vehicle seat cushion component having the density of either the preceding or succeeding item.

[0375] Item 56. A vehicle seat cushion component according to either of the preceding or following items, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently an extruded thermoplastic polymer.

[0376] Item 57. A vehicle seat cushion component according to either the preceding or following item, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0377] Item 58. A vehicle seat cushion component according to either of the preceding or following items, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently linear low-density polyethylene.

[0378] Item 59. A vehicle seat cushion component according to either of the preceding or following items, wherein the first plurality of three-dimensional filament rings, the second plurality of three-dimensional filament rings, and the third plurality of three-dimensional filament rings have a fineness of 200 decitex to 10,000 decitex.

[0379] Item 60. A first plastic mesh bolster comprising a first plurality of three-dimensional filament rings made of a first thermoplastic polymer, a second plastic mesh bolster comprising a second plurality of three-dimensional filament rings made of a second thermoplastic polymer, and a plastic mesh base comprising a third plurality of three-dimensional filament rings made of a third thermoplastic polymer, wherein the plastic mesh base has a first edge, a second edge, a first surface, and a second surface, and the first plastic mesh bolster A vehicle seat cushion component, combined with or not combined with either of the preceding or succeeding items, comprising a bolster attached to a plastic mesh base at a first edge, a second plastic mesh bolster attached to a plastic mesh base at a first edge, and a first plurality of three-dimensional filament rings, a second plurality of three-dimensional filament rings, and a third plurality of three-dimensional filament rings, each independently comprising a plastic mesh base including a plurality of fusion joints in which two rings are attached to each other.

[0380] Item 61. Vehicle seat cushion components are vehicle seat cushion components included in the back of a vehicle seat or the bottom of a vehicle seat, as described in either the preceding or following item.

[0381] Item 62. A vehicle seat cushion component as described in either of the preceding or following items, wherein the plastic mesh base is 60 to 95 volume percent air.

[0382] Item 63. A vehicle seat cushion component according to either the preceding or following item, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0383] Item 64. A vehicle seat cushion component, in combination with or uncombined with either of the preceding or succeeding items, comprising: a first bolster assembly including a first core cushion portion enclosed by a first outer bolster cover enclosed by a first bolster trim cover; a second bolster assembly including a second core cushion portion enclosed by a second outer bolster cover; and a trim cover portion having a first edge and a second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge and the second bolster assembly is sewn to the trim cover portion at the second edge.

[0384] Item 65. Vehicle seat cushion components are vehicle seat cushion components included in the back of a vehicle seat or the bottom of a vehicle seat, as described in either the preceding or following item.

[0385] Item 66. The first bolster assembly and the second bolster assembly are vehicle seat cushion components described in either the preceding or following item, each independently formed by compression molding.

[0386] Item 67. The first outer bolster cover and the second outer bolster cover are, independently, vehicle seat cushion components, including nonwoven fabric, as described in either the preceding or following item.

[0387] Item 68. The first outer bolster cover and the second outer bolster cover are, independently, vehicle seat cushion components, including natural fibers, as described in either the preceding or following item.

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

[0389] Item 70. A vehicle seat cushion component as described in either the preceding or following item, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently made of foamed polyurethane.

[0390] Item 71. A vehicle seat cushion component according to either of the preceding or following items, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer.

[0391] Item 72. A vehicle seat cushion component according to either of the preceding or following items, comprising multiple three-dimensional filament rings, including multiple fusion joints where two rings are attached to each other.

[0392] Item 73. A vehicle seat cushion component according to either of the preceding or following items, wherein at least a partial collection of rings within a plurality of three-dimensional filament rings are not parallel to or aligned with each other.

[0393] Item 74. The first core cushion portion, the second core cushion portion, and the central cushion portion are independently 60 to 95 volume percent air, as described in either the preceding or following item, for a vehicle seat cushion component.

[0394] Item 75. The first core cushion portion, the second core cushion portion, and the central cushion component each independently have a weight of approximately 0.01 g / cm³. 3 ~0.200g / cm 3 A vehicle seat cushion component having the density of either the preceding or succeeding item.

[0395] Item 76. A thermoplastic polymer is an extruded thermoplastic polymer, which is a vehicle seat cushion component as described in either the preceding or following item.

[0396] Item 77. A vehicle seat cushion component according to either the preceding or following item, wherein the thermoplastic polymer is composed of a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0397] Item 78. A vehicle seat cushion component described in either of the preceding or following items, which is a thermoplastic polymer that is biodegradable or recyclable.

[0398] Item 79. A vehicle seat cushion component as described in either of the preceding or following items, comprising multiple three-dimensional filament rings having a fineness of 200 decitex to 10,000 decitex.

[0399] Item 80. A vehicle seat cushion component as described in either the preceding or following item, further comprising providing sound dampening and temperature buffering.

[0400] Item 81. A vehicle seat, in combination with or not in combination with any of the preceding or following items, comprising: a seat base having a seat base frame; a seat back attached to the seat base and comprising a seat back frame; and a vehicle seat cushion component attached to the seat base frame and / or seat back frame, wherein the vehicle seat cushion component comprises: a first bolster assembly including a first core cushion portion enclosed by a first outer bolster cover enclosed by a first bolster trim cover; a second bolster assembly including a second core cushion portion enclosed by a second outer bolster cover enclosed by a second bolster trim cover; and a trim cover portion having a first edge and a second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge and the second bolster assembly is sewn to the trim cover portion at the second edge.

[0401] Item 82. The first outer bolster cover and the second outer bolster cover are each, independently, a vehicle seat made of nonwoven fabric as described in either the preceding or following item.

[0402] Item 83. The first outer bolster cover and the second outer bolster cover are, independently, vehicle seats made of natural fibers as described in either the preceding or following item.

[0403] Item 84. A vehicle seat cushion component further comprising a central cushion component positioned within an opening defined by a trim cover portion, as described in either the preceding or following item.

[0404] Item 85. A vehicle seat as described in either the preceding or following item, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently made of foamed polyurethane.

[0405] Item 86. A vehicle seat according to either of the preceding or following items, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer.

[0406] Item 87. A vehicle seat according to either of the preceding or following items, comprising multiple three-dimensional filament rings, including multiple fusion joints formed by two rings being attached to each other.

[0407] Item 88. A vehicle seat as described in either of the preceding or following items, wherein at least a partial collection of rings within a plurality of three-dimensional filament rings are not parallel to or aligned with one another.

[0408] Item 89. A vehicle seat as described in either the preceding or following item, wherein the first core cushion portion and the second core cushion portion consist of 60 to 95 volume percent air.

[0409] Item 90. The first core cushion portion and the second core cushion portion each independently contain approximately 0.01 g / cm³ of material. 3 ~0.200g / cm 3 A vehicle seat having the density of either the preceding or succeeding item.

[0410] Item 91. The thermoplastic polymer is an extruded thermoplastic polymer, which is used for vehicle seats as described in either the preceding or following item.

[0411] Item 92. A vehicle seat cushion component, in combination with or not in combination with either of the preceding or following items, comprising: a plastic mesh base, the plastic mesh base comprising a plurality of three-dimensional filament rings, the three-dimensional filament rings being made of a thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first face, and a second face; a first foam bolster attached to the plastic mesh base at the first edge; and a second foam bolster attached to the plastic mesh base at the second edge.

[0412] Item 93. Vehicle seat cushion components are vehicle seat cushion components included in the back of a vehicle seat or the bottom of a vehicle seat, as described in either the preceding or following item.

[0413] Item 94. A vehicle seat cushion component according to either of the preceding or following items, comprising multiple three-dimensional filament rings, including multiple fusion joints where two rings are attached to each other.

[0414] Item 95. A first foam bolster and a second foam bolster, each independently composed of a foam polymer, are vehicle seat cushion components as described in either the preceding or following item.

[0415] Item 96. A vehicle seat cushion component as described in either the preceding or following item, comprising a first foam bolster and a second foam bolster, each independently composed of foamed polyurethane.

[0416] Item 97. The first foam bolster and the second foam bolster are vehicle seat cushion components described in either the preceding or following item, each at least partially positioned on the first surface.

[0417] Item 98. A vehicle seat cushion component according to either of the preceding or following items, wherein a first foam bolster is attached to a first edge and a second foam bolster is attached to a second edge.

[0418] Item 99. A vehicle seat cushion component according to either of the preceding or following items, wherein a first foam bolster is attached to a plastic mesh base using a first retaining clip, the first foam bolster is attached to a plastic mesh base using a second retaining clip, and the first retaining clip and the second retaining clip each have an end embedded in the foam of the respective first foam bolster or second foam bolster and a retaining clip end attached to the plastic mesh base.

[0419] Item 100. A vehicle seat cushion component according to either of the preceding or following items, wherein at least a partial collection of rings within a plurality of three-dimensional filament rings are not parallel to or aligned with one another.

[0420] Item 101. A vehicle seat cushion component as described in either of the preceding or following items, wherein the rings within a plurality of three-dimensional filament rings are randomly oriented.

[0421] Item 102. A vehicle seat cushion component as described in either of the preceding or following items, wherein the plastic mesh base is 60 to 95 volume percent air.

[0422] Item 103. The plastic mesh base has a density of approximately 0.01 g / cm³. 3 ~0.200g / cm 3A vehicle seat cushion component having the density of either the preceding or succeeding item.

[0423] Item 104. A thermoplastic polymer is an extruded thermoplastic polymer, which is a vehicle seat cushion component as described in either the preceding or following item.

[0424] Item 105. A vehicle seat cushion component according to either the preceding or following item, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0425] Item 106. A thermoplastic polymer, including linear low-density polyethylene, is a vehicle seat cushion component as described in either the preceding or following item.

[0426] Item 107. Multiple three-dimensional filament rings having a fineness of 200 decitex to 10,000 decitex, a vehicle seat cushion component as described in either the preceding or following item.

[0427] Item 108. A vehicle seat cushion component comprising a plastic mesh base, comprising a plurality of three-dimensional filament rings, the three-dimensional filament rings being made of a thermoplastic polymer, in combination with or uncombined with either of the preceding or succeeding items.

[0428] Item 109. Vehicle seat cushion components are vehicle seat cushion components included in the back of a vehicle seat or the bottom of a vehicle seat, as described in either the preceding or following item.

[0429] Item 110. A vehicle seat cushion component according to either of the preceding or following items, comprising multiple three-dimensional filament rings, including multiple fusion joints where two rings are attached to each other.

[0430] Item 111. A vehicle seat cushion component as described in either of the preceding or following items, wherein the rings within a plurality of three-dimensional filament rings are randomly oriented.

[0431] Item 112. A vehicle seat cushion component as described in either of the preceding or following items, wherein the plastic mesh base is 60 to 95 volume percent air.

[0432] Item 113. A vehicle seat cushion component according to either of the preceding or following items, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

[0433] Item 114. An assembly, combined with or not combined with either of the preceding or succeeding items, comprising at least one piece of fabric sized to be displaceable across the surface of a cushion, and at least one retainer bonded to the at least one piece of fabric along the periphery of the fabric to receive a trim piece, actuator, heat transfer layer, or any combination thereof.

[0434] Item 115. An assembly described in either the preceding or succeeding item, further comprising a cushion.

[0435] Item 116. A cushion is an assembly described in either of the preceding or following items, further comprising a filamentous or mesh-like material.

[0436] Item 117. An assembly according to either of the preceding or following items, further comprising a trim cover sized to at least partially enclose a cushion and at least one piece of fabric, wherein the trim cover is coupled to at least one retainer.

[0437] Item 118. An assembly described in either the preceding or following item, comprising at least one retainer, including at least one clamping ring.

[0438] Item 119. An assembly described in either the preceding or succeeding item, in which at least one retainer is not directly coupled to the cushion.

[0439] Item 120. An assembly according to either of the preceding or following items, wherein at least one fabric further comprises a nonwoven material.

[0440] Item 121. Nonwoven materials, further comprising jute, as described in either the preceding or following item.

[0441] Item 122. A seat assembly comprising a seat base, a seat back, and a seat trim assembly located on the seat base or seat back as described in either the preceding or following item.

[0442] Item 123. A product formed by combining or not combining with either of the preceding or succeeding items, comprising: coupling at least one retainer to the periphery of at least one piece of fabric; stacking at least one piece of fabric on a cushion; and coupling trim parts, actuators, heat transfer layers, or any combination thereof to at least one retainer.

[0443] Item 124. A product formed by a method of either the preceding or succeeding item, further comprising compressing at least one piece of fabric to the contour of a cushion before stacking at least one piece of fabric on top of the cushion.

[0444] Item 125. A product formed by the method of either the preceding or succeeding item, further comprising attaching a trim cover, sized to at least partially enclose a cushion and at least one piece of fabric, to at least one retainer.

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

[0446] Item 127. A product formed by a method of either the preceding or succeeding item, further comprising not directly bonding at least one retainer to the cushion.

[0447] Item 128. A product formed by a method of either the preceding or succeeding item, further comprising clamping at least one clamping ring to a fabric as at least one retainer.

[0448] Item 129. A seat assembly comprising a seat base, a seat back, and a product located on the seat base or seat back as described in either the preceding or following item.

[0449] Item 130. A method, in combination with or without combination with any of the preceding or succeeding items, comprising: coupling at least one retainer to the periphery of at least one piece of fabric; stacking at least one piece of fabric on a cushion; and coupling trim parts, actuators, heat transfer layers, or any combination thereof to at least one retainer.

[0450] Item 131. The method of either the preceding or following item, further comprising enclosing the cushion and at least one piece of fabric at least partially by attaching the trim cover to at least one retainer.

[0451] Item 132. The method according to either of the preceding or following items, wherein at least one fabric further comprises a nonwoven material.

[0452] Item 133. A trim assembly manufactured from the method described in either the preceding or succeeding item.

[0453] Item 134. A member comprising a filamentous mesh-like material, wherein the member defines a first end region and a second end region, the first and second end regions being bounded by the outer circumference of the member, the member comprising a cushion, in combination with or uncombined with either a preceding or succeeding item, wherein the first end region is positioned at a non-zero angle with respect to the second end region.

[0454] Item 135. A cushion according to either the preceding or following item, wherein the component is formed solely from a filamentous or mesh-like material.

[0455] Item 136. A cushion according to either of the preceding or following items, comprising a polymer network having a plurality of integrated polymer filaments.

[0456] Item 137. A cushion according to either the preceding or following item, wherein the first end region is molded to define a seat back cushion, and the second end region is molded to define a seat base cushion.

[0457] Item 138. A cushion according to either of the preceding or following items, further comprising a first surface for supporting a occupant on the cushion and a second surface opposite to the first surface, wherein the first surface extends across a first end region and a second end region, and the second surface extends across the first end region and a second end region.

[0458] Item 139. A cushion according to either the preceding or following item, wherein the member defines one or more grooves, each groove intersecting with one of the first surface and the second surface.

[0459] Item 140. A cushion according to either the preceding or following item, wherein the groove extends transversely across the member and is positioned between a first end region and a second end region.

[0460] Item 141. A cushion according to either the preceding or succeeding item, comprising a groove, a first surface and a second surface, the first surface and the second surface fitting together.

[0461] Item 142. A cushion according to either of the preceding or following items, further comprising one or more grooved fastening portions connecting a first surface to a second surface in order to hold a first end region at a non-zero angle with respect to a second end region.

[0462] Item 143. A cushion according to either the preceding or succeeding item, further comprising one or more secondary members supported by a member.

[0463] Item 144. The secondary component is a cushion described in either the preceding or following item, including a filamentous or mesh-like material.

[0464] Item 145. A secondary member is a cushion according to either the preceding or following item, extending outward from at least one of the first end region and the second end region of the member.

[0465] Item 146. A cushion according to either the preceding or following item, further comprising one or more secondary member fastening portions for connecting secondary members to a member.

[0466] Item 147. A secondary member is a cushion as described in either the preceding or following item, which is molded to form a side bolster or lumbar support pad and positioned on the member.

[0467] Item 148. A seat assembly comprising a frame and a cushion, supported by the frame, as described in either the preceding or succeeding item.

[0468] Item 149. A die for defining a series of openings arranged to extrude material for a filamentous mesh material member for a cushion described in either the preceding or succeeding item, the series of openings being arranged to define the outer periphery of a member including a seat back region and a seat base region.

[0469] Item 150. A tool as described in either the preceding or succeeding item, wherein a series of openings are further arranged such that the outer circumference defines one or more grooves for a member.

[0470] Item 151. A tool according to either of the preceding or following items, wherein a series of openings are arranged such that one or more grooves are positioned between the seat back region and the seat base region.

[0471] Item 152. A method, in combination with or without any of the preceding or succeeding items, comprising positioning a first end region of a filamentous mesh material member at a non-zero angle with respect to a second end region of the member, and holding the first end region at a non-zero angle with respect to the second end region.

[0472] Item 153. A method of either the preceding or succeeding item, further comprising forming a filamentous mesh material member by extruding a material through a die.

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

[0474] Item 155. The method of either the preceding or following item, further comprising pouring extruded material from a die through a funnel to form a filamentous mesh material member.

[0475] Item 156. The method of either the preceding or succeeding item, further comprising moving the extruded material behind a funnel via one or more rollers.

[0476] Item 157. A method of either the preceding or succeeding item, further comprising forming one or more grooves during at least one of extruding a material, pouring an extruded material, and moving an extruded material.

[0477] Item 158. A method of either the preceding or succeeding item, further comprising cutting one or more grooves into a member.

[0478] Item 159. The method of either the preceding or following item, further comprising inserting one or more fasteners into opposing sides of a groove and / or joining the opposing sides of a groove in order to hold a first end region relative to a second end region.

[0479] Item 160. The method of either the preceding or succeeding item, further comprising cutting an extruded material to form an outer surface of a member, wherein the outer surface extends over a first end region and a second end region.

[0480] Item 161. The method of either the preceding or succeeding item, further comprising bending a filamentous mesh material member from a first position to a second position in order to orient the member.

[0481] Item 162. A method of either the preceding or succeeding item, further comprising attaching one or more secondary members to a member.

[0482] Item 163. The method of either the preceding or succeeding item, further comprising forming a secondary member from a filamentous mesh material.

[0483] Item 164. Attaching a secondary member to a member, the method of either the preceding or following item, further comprising inserting one or more fasteners into the secondary member and / or joining the secondary member to the member.

[0484] Item 165. The method of either the preceding or succeeding item, further comprising attaching a component to the frame of a seat assembly to provide a cushion therefor.

[0485] Item 166. Any combination of any of the preceding items 1 through 165.

[0486] While various embodiments have been described above, these embodiments are not intended to describe all possible forms of the Disclosure. In this regard, it should be understood that the terms used herein are descriptive rather than restrictive, and that various modifications may be made without departing from the spirit and scope of the Disclosure. In addition, features of various embodiments can be combined to form further embodiments of the Disclosure.

Claims

1. A seat support, a) A plurality of flat layers attached to a seat frame and supporting a passenger on the seat frame, wherein the plurality of flat layers are stacked on top of each other, and each of the plurality of stacked layers has a different density, b) Multiple layers or regions of a plastic mesh, wherein the multiple layers or regions are stacked, attached, or positioned relative to each other at a non-zero angle, c) A first bolster assembly including a first core cushion portion surrounded by a first outer bolster cover surrounded by a first bolster trim cover, a second bolster assembly including a second core cushion portion surrounded by a second outer bolster cover, and a trim cover portion having a first edge and a second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge and the second bolster assembly is sewn to the trim cover portion at the second edge, the first bolster assembly, the second bolster assembly and the trim cover portion, d) A plastic mesh base comprising a plurality of three-dimensional filament rings, the three-dimensional filament rings being made of a thermoplastic polymer, the plastic mesh base having a first edge, a second edge, a first face, and a second face, a plastic mesh base, a first foam bolster attached to the plastic mesh base at the first edge, and a second foam bolster attached to the plastic mesh base at the second edge and / or e) At least one piece of fabric sized to be displaceable across the surface of the cushion, and at least one retainer bonded to the at least one piece of fabric along the periphery of the fabric to receive trim parts, actuators, heat transfer layers, or any combination thereof. A seat support equipped with a seat support.

2. The seat support according to claim 1, further comprising a plurality of flat layers attached to the seat frame and supporting the occupant on the seat frame, wherein the plurality of flat layers are stacked on top of each other and each of the plurality of stacked layers has a different density.

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

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

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

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

7. The seat support according to any one of claims 1 to 6, wherein each continuous pair of the plurality of stacked layers is welded, sewn, fastened or bonded together.

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

9. The seat support according to any one of claims 1 to 8, wherein the plurality of stacked layers further include a base layer adapted to be attached to the seat frame, the base layer being formed of a material denser than the other layers of the plurality of stacked layers.

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

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

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

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

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

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

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

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

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

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

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

21. The seat frame is attached to the seat frame and further comprises the plurality of layers that support the passenger on the seat frame, the plurality of layers being stacked on top of each other, At least one of the aforementioned stacked layers has a generally uniform thickness, Each of the aforementioned stacked layers is formed integrally, The seat support according to any one of claims 1 to 20, wherein each of the plurality of stacked layers is pivotably connected to one another.

22. The plurality of layers of the plastic mesh-like body are, A first plastic mesh bolster comprising a first plurality of three-dimensional filament rings composed of a first thermoplastic polymer, A second plastic mesh bolster comprising a second plurality of three-dimensional filament rings composed of a second thermoplastic polymer, A plastic mesh base comprising a third plurality of three-dimensional filament rings composed of a third thermoplastic polymer, wherein the plastic mesh base has a first edge, a second edge, a first face, and a second face, the first plastic mesh bolster is attached to the plastic mesh base at the first edge, and the second plastic mesh bolster is attached to the plastic mesh base at the first edge, The seat support according to claim 1, further comprising the following:

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

24. The seat support according to claim 22 or 23, wherein each of the first plurality of three-dimensional filament rings, the second plurality of three-dimensional filament rings, and the third plurality of three-dimensional filament rings independently includes a plurality of fusion joints formed by two rings being attached to each other.

25. The seat support according to any one of claims 22 to 24, wherein the first plurality of three-dimensional filament rings and the second plurality of three-dimensional filament rings are each independently molded into a form for a vehicle seat bolster.

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

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

28. The seat support according to any one of claims 22 to 29, wherein the first plastic mesh bolster and the second plastic mesh bolster are attached to the plastic mesh base by face strips, adhesives, retaining clips and / or hog rings.

29. The seat support according to any one of claims 22 to 30, wherein at least a portion of the rings in the first plurality of three-dimensional filament rings, at least a portion of the rings in the second plurality of three-dimensional filament rings, and at least a portion of the rings in the third plurality of three-dimensional filament rings are not parallel to each other or aligned.

30. The seat support according to any one of claims 22 to 31, wherein at least a portion of the rings in the first plurality of three-dimensional filament rings, at least a portion of the rings in the second plurality of three-dimensional filament rings, and at least a portion of the rings in the third plurality of three-dimensional filament rings are randomly oriented.

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

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

33. The seat support according to any one of claims 22 to 34, wherein the first plastic mesh bolster, the first plastic mesh bolster, and the plastic mesh base each independently contain 60 to 95 volume percent of air.

34. The first plastic mesh bolster, the first plastic mesh bolster, and the plastic mesh base each independently contain approximately 0.01 g / cm³ of plastic mesh. ３ ~0.200g / cm ３ A seat support according to any one of claims 22 to 35, having the density of the following:

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

36. The seat support according to any one of claims 22 to 37, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

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

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

39. The plurality of layers of the plastic mesh-like body are, A first plastic mesh bolster comprising a first plurality of three-dimensional filament rings composed of a first thermoplastic polymer, A second plastic mesh bolster comprising a second plurality of three-dimensional filament rings composed of a second thermoplastic polymer, A plastic mesh base comprising a third plurality of three-dimensional filament rings made of a third thermoplastic polymer, wherein the plastic mesh base has a first edge, a second edge, a first face, and a second face, the first plastic mesh bolster is attached to the plastic mesh base at the first edge, the second plastic mesh bolster is attached to the plastic mesh base at the first edge, and the first plurality of three-dimensional filament rings, the second plurality of three-dimensional filament rings, and the third plurality of three-dimensional filament rings each independently comprises a plurality of fusion joints in which two rings are attached to each other, The seat support according to claim 1, further comprising the following:

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

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

42. The seat support according to any one of claims 22 to 43, wherein the first thermoplastic polymer, the second thermoplastic polymer, and the third thermoplastic polymer are each independently composed of a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

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

44. The seat support according to any one of claims 1 to 45, wherein the vehicle seat cushion component is included in the back of the vehicle seat or the bottom of the vehicle seat.

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

46. The seat support according to any one of claims 45 to 47, wherein the first outer bolster cover and the second outer bolster cover each independently comprise a nonwoven fabric.

47. The seat support according to any one of claims 45 to 48, wherein the first outer bolster cover and the second outer bolster cover each independently contain natural fibers.

48. The seat support according to any one of claims 45 to 49, further comprising a central cushion component positioned within an opening defined by the trim cover portion.

49. The seat support according to any one of claims 45 to 50, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently made of foamed polyurethane.

50. The seat support according to any one of claims 45 to 51, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are each independently composed of a plurality of three-dimensional filament rings made of a thermoplastic polymer.

51. The seat support according to any one of claims 45 to 52, wherein the plurality of three-dimensional filament rings include a plurality of fusion-bonded connections where two rings are attached to each other.

52. The seat support according to any one of claims 45 to 53, wherein at least the partial collections of rings within the plurality of three-dimensional filament rings are not parallel to each other or aligned with each other.

53. The seat support according to any one of claims 45 to 54, wherein the first core cushion portion, the second core cushion portion, and the central cushion component are independently composed of 60 to 95 volume percent air.

54. The first core cushion portion, the second core cushion portion, and the central cushion component each independently have a density of approximately 0.01 g / cm³. ３ ~0.200g / cm ３ A seat support according to any one of claims 45 to 55, having the density of

55. The seat support according to any one of claims 45 to 56, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

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

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

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

59. A seat support according to any one of claims 45 to 60, further comprising providing sound dampening and temperature buffering.

60. Vehicle seat cushion components are also included. The seat cushion component for the vehicle is The plastic mesh base comprises a plurality of three-dimensional filament rings, the three-dimensional filament rings are made of the thermoplastic polymer, and the plastic mesh base has a first edge, a second edge, a first surface, and a second surface. The first foam bolster is attached to the plastic mesh base at the first edge, The second foam bolster is attached to the plastic mesh base at the second edge, A seat support according to claim 1, comprising:

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

62. The seat support according to claim 62 or 63, wherein the plurality of three-dimensional filament rings include a plurality of fusion-bonded connections where two rings are attached to each other.

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

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

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

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

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

68. The seat support according to any one of claims 62 to 69, wherein at least the partial collections of rings within the plurality of three-dimensional filament rings are not parallel to each other or aligned.

69. The seat support according to any one of claims 62 to 70, wherein the rings within the plurality of three-dimensional filament rings are randomly oriented.

70. The seat support according to any one of claims 62 to 71, wherein the plastic mesh base is 60 to 95 volume percent air.

71. The plastic mesh base has a density of approximately 0.01 g / cm³. ３ ~0.200g / cm ３ A seat support according to any one of claims 62 to 72, having the density of the following:

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

73. The seat support according to any one of claims 62 to 74, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

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

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

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

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

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

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

80. The seat support according to any one of claims 78 to 81, wherein the plastic mesh base is 60 to 95 volume percent air.

81. The seat support according to any one of claims 78 to 82, wherein the thermoplastic polymer comprises a component selected from the group consisting of polyolefins, polystyrene-based thermoplastic elastomers, polyester-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers.

82. Further assembly The aforementioned assembly is The at least one piece of fabric, sized to be displaceable across the surface of the cushion, The at least one fabric is coupled along the periphery of the fabric and has the at least one retainer that accepts the trim part, the actuator, the heat transfer layer, or any combination thereof. The seat support according to claim 1, further comprising the following:

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

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

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

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

87. The seat support according to claims 84 to 88, wherein the at least one retainer is not directly bonded to the cushion.

88. The seat support according to claims 84 to 89, wherein the at least one fabric further comprises a nonwoven material.

89. The seat support according to claim 80, wherein the nonwoven material further comprises jute.

90. A member comprising a filamentous mesh-like material as the plastic mesh-like body, wherein the member defines a first end region and a second end region, and the first end region and the second end region are bounded by the outer circumference of the member, further comprising the member, The seat support according to claim 1, wherein the first end region is positioned at a non-zero angle with respect to the second end region.

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

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

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

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

95. The seat support according to claim 96, wherein the member defines one or more grooves, and each groove intersects with one of the first surface and the second surface.

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

97. The seat support according to claim 97 or 98, wherein the groove comprises a first surface and a second surface, and the first surface and the second surface fit together with each other.

98. The seat support according to claim 99, further comprising one or more groove fastening portions connecting the first surface to the second surface in order to hold the first end region at the non-zero angle with respect to the second end region.

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

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

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

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

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

104. A base material adapted to be attached to the seat frame, A seat support according to any one of claims 1 to 105, which is stacked on the substrate, A seat assembly comprising:

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

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

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

108. Seat frame and A seat support according to any one of claims 1 to 105, which is attached to or supported by the seat frame, A seat assembly comprising:

109. The bottom of the seat and The back of the seat and, A seat support according to any one of claims 1 to 105, located at the bottom of the seat or the back of the seat, A seat assembly comprising:

110. A seat for a vehicle, A seat base having a seat base frame, The seat back is attached to the bottom of the seat and includes a seat back frame, A seat support according to any one of claims 1 and 45 to 61, wherein the seat support further comprises a vehicle seat cushion component attached to the seat bottom frame and / or the seat back frame, the vehicle seat cushion component is The first bolster assembly includes the first core cushion portion surrounded by the first outer bolster cover, which is surrounded by the first bolster trim cover, The second bolster assembly includes the second core cushion portion surrounded by the second outer bolster cover, which is surrounded by the second bolster trim cover, The trim cover portion having the first edge and the second edge, wherein the first bolster assembly is sewn to the trim cover portion at the first edge and the second bolster assembly is sewn to the trim cover portion at the second edge, A vehicle seat equipped with the following features.

111. The vehicle seat according to claim 112, wherein the first outer bolster cover and the second outer bolster cover each independently include a nonwoven fabric.

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

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

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

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

116. The vehicle seat according to any one of claims 112 to 117, wherein the plurality of three-dimensional filament rings include a plurality of fusion-bonded connections where two rings are attached to each other.

117. The vehicle seat according to any one of claims 112 to 118, wherein at least the partial collections of rings within the plurality of three-dimensional filament rings are not parallel to each other or aligned.

118. The vehicle seat according to any one of claims 112 to 119, wherein the first core cushion portion and the second core cushion portion are composed of 60 to 95 volume percent air.

119. The first core cushion portion and the second core cushion portion each independently have a density of approximately 0.01 g / cm³. ３ ~0.200g / cm ３ A vehicle seat according to any one of claims 112 to 120, having the density of .

120. The vehicle seat according to any one of claims 112 to 121, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

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

122. The tool according to claim 123, wherein the series of openings are further arranged such that the outer circumference defines one or more grooves for the member.

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

124. A method for manufacturing a product, a) The first lower process, i) Unwinding the first sheet of the first material, ii) Cutting the first seat support layer from the first sheet, iii) Installing the aforementioned first seat support layer on a substrate, iv) Unwinding a second sheet of a second material having a density lower than that of the first material, v) Cutting the second seat support layer from the second seat, vi) Installing the second seat support layer on the first seat support layer, The first lower process includes, b) A second lower process, i) Forming multiple layers or regions of a plastic mesh-like structure, ii) stacking or attaching the multiple layers or regions, or positioning the multiple cushion portions at a non-zero angle to each other, A second lower process, c) A third lower process, i) sewing a first bolster assembly having a first core cushion portion enclosed by a first outer bolster cover enclosed by a first bolster trim cover to the first edge of the trim cover portion, ii) Sewing a second bolster assembly having a second core cushion portion enclosed by a second outer bolster cover to the second edge of the trim cover portion, A third lower process, including d) A fourth sub-process, i) Attaching a first foam bolster to a first edge of a plastic mesh base, wherein the plastic mesh base includes a plurality of three-dimensional filament rings, and the three-dimensional filament rings are made of a thermoplastic polymer, ii) Attaching the second foam bolster to the second edge of the plastic mesh base, A fourth lower step and / or, e) A fifth sub-process, i) At least one retainer is attached to the periphery of at least one piece of fabric, ii) Stacking at least one of the fabrics on top of the cushion, iii) Connecting trim components, actuators, heat transfer layers, or any combination thereof to at least one retainer, A fifth sub-process, including Methods that include...

125. The method according to claim 126, further comprising the first lower step.

126. Unwinding a third sheet of a third material having a density lower than that of the second material, Cutting the third seat support layer from the aforementioned third seat, The third seat support layer is placed on the second seat support layer, The method according to claim 126 or 127, further comprising:

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

128. The method according to claim 126, further comprising the second lower step.

129. The method according to claim 126 or 130, further comprising molding the plurality of cushion portions.

130. The method according to any one of claims 126, 130, and 131, further comprising forming the plurality of cushion portions as a single sheet.

131. The method according to claim 132, further comprising folding the cushion portions so that they are stacked on top of each other.

132. The method according to claim 133, further comprising forming at least one recess in at least one of the plurality of cushion portions in order to fold the cushion portion.

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

134. The method according to claim 126, further comprising the fifth lower step.

135. The method according to claim 136, further comprising connecting a trim cover to the at least one retainer to at least partially surround the cushion and the at least one fabric.

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

137. Positioning the first end region of the filamentous mesh material member of the plurality of cushion portions at a non-zero angle with respect to the second end region of the member, The first end region is held at a non-zero angle with respect to the second end region, The method according to claim 16, further comprising:

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

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

140. The method according to claim 140 or 141, further comprising pouring the extruded material from the die through a funnel to form the filamentous mesh material member.

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

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

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

144. The method according to claim 144 or 145, further comprising inserting one or more fastening portions into opposing sides of the groove and / or joining the opposing sides of the groove in order to hold the first end region relative to the second end region.

145. The method according to any one of claims 140 to 146, further comprising cutting the extruded material to form the outer surface of the member, wherein the outer surface extends over the first end region and the second end region.

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

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

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

149. The method according to claim 149 or 150, wherein attaching the secondary member to the member further includes inserting one or more fastening portions into the secondary member and the member and / or connecting the secondary member to the member.

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

151. A method for designing seat cushions, To obtain a design for an integrated seat cushion, Redesigning the aforementioned integrated seat cushion design into multiple stacked, sewn, or attached cushion portion designs, Methods that include...

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

153. A method for manufacturing a seat cushion, Designing a plurality of cushioning component designs as described in claim 153 or 154, The plurality of cushion portions are formed from an extruded thermoplastic resin mesh, Methods that include...

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

155. A seat support manufactured by the method described in any one of claims 139 to 152 or designed by the method described in any one of claims 153 to 56.

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

157. A seat assembly manufactured by the method described in claim 158.

158. The at least one retainer is attached to the periphery of the at least one piece of fabric, The process involves stacking at least one of the aforementioned fabrics on top of the cushion, The trim components, the actuator, the heat transfer layer, or any combination thereof are coupled to the at least one retainer. A seat support manufactured by the method of claim 157, including the method of claim 157.

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

160. A seat support manufactured by the method of claim 160 or 161, further comprising connecting a trim cover, which is sized to at least partially enclose the cushion and the at least one fabric, to the at least one retainer.

161. A seat support manufactured by the method of claims 160 to 162, wherein stacking the at least one fabric on the cushion further includes stacking the at least one fabric on a filamentous mesh material cushion.

162. A seat support manufactured by the method of claims 160 to 163, further comprising not directly bonding the at least one retainer to the cushion.

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

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

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

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