Cushions, manufacturing systems, and manufacturing methods

Abstract

This invention provides a filament mesh structure such as a cushion that can be applied to a seat assembly, as well as a manufacturing system and method for the same. [Solution] The cushion comprises a set of yarns, each member of the set of yarns having a yarn mesh structure that is coupled to at least one other member of the set of yarns and defines a first side surface, and a layer that is positioned on the first side surface and coupled to at least some members of the set of yarns.

Description

Technical Field

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 508,300 (filed Jun. 15, 2023) and Danish Patent Application No. PA202370560 (filed Nov. 3, 2023), the disclosures of which are hereby incorporated by reference in their entirety.

[0002] Various embodiments relate to a thread mesh structure such as a cushion, and a manufacturing system and method.

Brief Description of the Drawings

[0003] [Figure 1] FIG. 1 is a perspective view of an example of a seat assembly. [Figure 2] FIG. 2 is a perspective view of an example of a cushion of a seat assembly that is a thread mesh structure. [Figure 3] FIG. 3 is a schematic diagram of an example of a manufacturing system for manufacturing a thread mesh structure. [Figure 4] FIG. 4 is a schematic diagram of an example of a layer distribution subsystem for distributing a layer onto a thread mesh structure. [Figure 5] FIG. 5 is a schematic diagram of an example of a layer distribution subsystem for distributing a layer onto a thread mesh structure. [Figure 6] FIG. 6 is an enlarged view of an example of a layer coupled to a thread mesh structure. [Figure 7] FIG. 7 is a flowchart of an example of a method of forming a thread mesh structure. [[ID=3,6]] [Figure 8] FIG. 8 is a plan view of an example of a layer disposed on a thread mesh structure and including straight threads. [Figure 9] FIG. 9 is a plan view of an example of a layer disposed on a thread mesh structure and including non-straight threads. [Figure 10] FIG. 10 is a plan view of an example of a layer disposed on a thread mesh structure and including continuous threads. [Figure 11]Figure 11 is a perspective view of an example of a layer containing a film placed on a filament mesh structure. [Figure 12] Figure 12 is a perspective view of an example of a layer containing yarn and film arranged on a yarn mesh structure. [Figure 13] Figure 13 is a perspective view of an example of layers arranged on multiple sides of a filament mesh structure. [Figure 14] Figure 14 is a perspective view of an example of layers and ports provided in layers, arranged on all sides of a filament mesh structure. [Figure 15a] Figure 15a shows an example of applying layers to multiple sides of a filament mesh structure by rotating the filament mesh structure. [Figure 15b] Figure 15b shows an example of distributing layers to multiple sides of a filament mesh structure by rotating the filament mesh structure. [Figure 15c] Figure 15c shows an example of distributing layers to multiple sides of a filament mesh structure by rotating the filament mesh structure. [Modes for carrying out the invention]

[0004] Detailed explanation Embodiments are described in detail here, with examples shown in the accompanying drawings. The following detailed description includes numerous specific details to provide a complete understanding of the various embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described can be carried out without these specific details. In other examples, well-known methods, procedures, components, circuits, and networks are not described in detail so as not to unnecessarily obscure the aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely illustrative and that various alternative forms are possible. The drawings are not necessarily to scale. Some features may be exaggerated or minimized to illustrate the details of certain components. Accordingly, certain structural and functional details disclosed herein should not be construed as limiting, but merely as representative grounds to teach those skilled in the art how to use the embodiments provided herein in various ways.

[0006] "One or more" includes a function performed by one element, a function performed by multiple elements, for example in a distributed manner, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0007] While terms such as "first," "second," etc., are used in this specification to describe various elements in some examples, it will 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 embodiments described, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact. The first contact and the second contact are both contacts, but they are not the same contact.

[0008] The terms used in the description of the various embodiments described herein are intended solely to describe and not to limit a particular embodiment. In the description of the various embodiments described and the accompanying claims, the singular forms “a,” “an,” and “the” also include the plural form unless explicitly indicated otherwise in the context. The terms “and / or” as used herein shall be understood to refer to and encompass one or any possible combination of the enumerated items relating to the description. The terms “includes,” “including,” “comprises,” and / or “comprising,” as used herein, specify the presence of the described features, figures, steps, actions, elements, and / or components, but shall not exclude the presence or addition of one or more other features, figures, steps, actions, elements, components, and / or sets thereof.

[0009] As used herein, the term "if" is optionally interpreted to mean, depending on the context, "when," "on the occasion of," "in response to a decision," or "in response to detection." Similarly, the phrases "when determined" or "[the described condition or event] is detected" are optionally interpreted to mean, depending on the context, "when determined," "in response to a determination," "[the described condition or event] is detected," or "[the described condition or event] is detected."

[0010] Referring to Figure 1, an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for land vehicles such as automobiles, trucks, and buses, or for non-land vehicles such as aircraft or ships. For example, a seat assembly 10 for land vehicles may be molded and sized as a front driver's seat or passenger seat, a second, third, or other rear seat, and may include bench-style seats, bucket seats, or other seat styles. Furthermore, the seat assembly 10 may be a non-retractable seat, or a retractable seat that can be folded and stored in a cavity in the vehicle floor. Furthermore, the seat assembly 10 may be configured for non-vehicle applications such as furniture.

[0011] In the configuration shown in Figure 1, the seat assembly 10 includes a seat base 20 and a seat rear 22. The seat rear 22 is intended to be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool.

[0012] The seat base 20 is configured to receive a seated occupant and support the occupant's pelvis and thighs. The seat base 20 comprises a seat base frame 30, a cushion 32, and a trim cover 34.

[0013] The seat base frame 30 is a structure that supports the cushion 32. The seat base frame 30 comprises one or more structural members and may be made of any suitable material, such as a metal alloy, polymer material, thread-reinforced polymer material, or a combination thereof. In one or more configurations, the seat base frame 30 includes a panel, seat pan, suspension mat, or suspension wires on which the cushion 32 is placed.

[0014] The cushion 32 is positioned on the seat base frame 30. The cushion 32 is made of a compliant material that supports the seat occupant and distributes the load force from the seat occupant to the seat base frame 30. The cushion 32 and related manufacturing methods are described in more detail below.

[0015] The trim cover 34 covers at least a part of the cushion 32. Further, the trim cover 34 provides an outer surface visible to one or more eyes of the rear portion 22 of the seat. The seat occupant is disposed on the trim cover 34 when seated on the seat assembly 10. The trim cover 34 is made of any suitable material or plurality of materials such as fabric, leather, synthetic leather, vinyl, or combinations thereof. The trim cover 34 may include a plurality of trim panels assembled by any suitable method such as fusing or stitching. The trim cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may include trim attachment features that are attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 and to help conform the trim cover 34 to the contours of the seat bottom frame 30, the cushion 32, or both. Different types of trim attachment mechanisms may be used to attach the trim cover 34 to the seat bottom frame 30 instead of the cushion 32.

[0016] The rear portion 22 of the seat is configured to support the back of the seated occupant. The rear portion 22 of the seat is disposed adjacent to the seat bottom 20. For example, the rear portion 22 of the seat may be disposed above the seat bottom 20 and in the vicinity of the rear side of the seat bottom 20. The rear portion 22 of the seat extends in a generally upward direction away from the seat bottom 20. In some configurations, the rear portion 22 of the seat may be attached to the seat bottom 20 and pivotable relative to the seat bottom 20. In other configurations, the rear portion 22 of the seat is not attached to the seat bottom 20. For example, the rear portion of a vehicle seat may be attached to the structure of the vehicle body in some second row seat assemblies and the like. The rear portion 22 of the seat includes a rear seat frame 40, a cushion 42, a trim cover 44, and optionally a headrest 46.

[0017] The rear seat frame 40 is a structure that supports the cushion 42. The rear seat frame 40 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a yarn-reinforced polymer material, or a combination thereof. In one or more configurations, the rear seat frame 40 includes a panel, pan, suspension mat, or suspension wire on which the cushion 42 is disposed. Also, the rear seat frame 40 may be integrally formed with the seat bottom frame 30.

[0018] The cushion 42 is disposed on the rear seat frame 40. The cushion 42 is formed of a compliant material that supports the seat occupant and distributes the load from the seat occupant to the rear seat frame 40. The cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be formed separately from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods will be described in more detail below.

[0019] The trim cover 44 covers at least a portion of the cushion 42. Further, the trim cover 44 provides one or more visible outer surfaces of the rear seat 22. The seat occupant is disposed on the trim cover 44 when seated on the seat assembly 10. The trim cover 44 is made of any suitable material or combination of materials, such as fabric, leather, synthetic leather, vinyl, or a combination thereof. The trim cover 44 may include a plurality of trim panels assembled in any suitable manner, such as by fusion or stitching. The trim cover 44 is attached to the rear seat frame 40 or the cushion 42 or both. For example, the trim cover 44 may include trim attachment features that are attached to the rear seat frame 40, the cushion 42, or both to prevent removal of the trim cover 44 and to help conform the trim cover 44 to the contours of the rear seat frame 40, the cushion 42, or both. It is contemplated that different types of trim attachment mechanisms may be employed to attach the trim cover 44 to the rear seat frame 40 rather than the cushion 42.

[0020] The headrest 46, if provided, is configured to support the head of the seat occupant. The headrest 46 is located at the top of the rear of the seat 22 or at the end of the rear of the seat 22 opposite to the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the rear of the seat 22, or it may be formed integrally with the rear of the seat 22.

[0021] Referring to Figure 2, an example of cushion 50 is shown. For convenience of reference, the cushion is collectively designated as reference number 50. It should be understood that the structure and description of cushion 50 are applicable to cushion 32 on the seat base 20, cushion 42 on the rear of the seat 22, or both.

[0022] The cushion 50 is a non-foamed component or contains at least one non-foamed component. Non-foamed components are mainly called filament mesh structures, but may also be called mesh cushions, mesh structures, or twisted mesh. In Figure 2, the cushion 50 is shown as a non-foamed component that does not contain foamed components or foamed materials such as urethane or polyurethane foam. However, it is conceivable that the cushion 50 may also contain foamed components or foamed materials in addition to the non-foamed component to provide additional cushioning or localized cushioning for the seat occupant. For example, foamed material may be provided between the cushion 50 and trim covers (e.g., trim covers 34, 44) placed on, inside, or in combination with the cushion 50. Reducing the amount of foamed material provided to the cushion 50, or eliminating foamed material from the cushion 50, can reduce weight and improve support and comfort for the seat occupant.

[0023] Cushion 50 is described below in relation to cushion 50 that does not contain foaming material. In this regard, cushion 50 is made from filaments 52 of polymer material, which are randomly looped, bent, curled, or intertwined and bonded to one another, as will be discussed in more detail below. An enlarged view of cushion 50 with an example of filaments 52 is shown in Figure 6. The filaments 52 are bonded to other filaments 52 rather than indirectly bonded to a resin or other intermediate material.

[0024] The yarn 52, also called a strand or thread, is made from any suitable material or combination of materials. In some configurations, the yarn 52 is made from polymer materials or thermoplastic materials such as polyamide, polyester, polyimide, polyolefin (e.g., polypropylene, polyethylene, etc.), polystyrene, or combinations thereof. As an example, polyethylene yarn can be made from linear low-density polyethylene (LLPDE). Unlike foamed materials, yarn materials may be recyclable or may be more easily recyclable than foamed materials. The yarn 52 may also include reinforced yarns, and it is intended that the reinforced yarns do not have to be made from thermoplastic materials.

[0025] Depending on the configuration, the yarn 52 may be a monofilament made from a single material. Depending on the configuration, the yarn 52 may be made from multiple materials. For example, a yarn 52 made from multiple materials may include a core made from a first thermoplastic material and a sheath surrounding the core, made from a second thermoplastic material different from the first thermoplastic material. The cushion 50 is thought to include a combination of a monofilament and a yarn made from multiple materials that is not a monofilament.

[0026] Randomly looped, bent, looped, curled, or entangled yarns 52 are joined together such that one yarn 52 comes into contact with another yarn 52, thereby resulting in a lightweight, air-permeable cushion (e.g., cushions 32 and / or 42) or mesh structure with openings or gaps between the yarns 52. An example of a manufacturing system 60 for producing the cushion or yarn mesh structure is also shown in Figure 3. In this example, the manufacturing system 60 includes a material feed unit 70, an extruder 72, and a funnel 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0027] Referring to Figure 3, the material supply unit 70 holds the stock of material to be extruded, such as solid beads, flakes, granules, pellets, or powder made from the material. In some configurations, the material supply unit 70 is configured as a container or hopper. The material supply unit 70 supplies the stock of material to the extruder 72.

[0028] The extruder 72, which may also be called the first tool, melts the material stock and extrudes the material stock as a set of filaments 52. The extruder 72 may have any preferred configuration. In some configurations, the extruder 72 includes a rotatable screw and a barrel that receives a heating element. The rotation of the screw moves the material through the barrel and helps heat the material by friction generated as the screw rotates. The material is then pressed. The molten material exits the barrel and is transported to the mold 80 of the extruder 72.

[0029] The mold 80, also called a mold plate or extrusion mold, has multiple through-holes or filament-forming openings through which the molten material passes. One filament 52 is extruded from each through-hole. The filament 52 falls downward from the mold 80 into the funnel 74 under gravity.

[0030] The funnel 74 consolidates or groups the yarns 52 into a more compact arrangement in which the yarns bend, curl, or loop, and each yarn 52 is joined to at least one other yarn 52 by contact. The funnel 74 has a funnel inlet and a funnel outlet smaller than the funnel inlet. Individual, separated yarns 52 enter the funnel inlet. The yarns 52 bend, curl, or loop, and come into contact as they accumulate. The yarns 52 move through the funnel 74 toward the funnel outlet. Each member of the set of yarns 52 may be joined to at least one other member of the set of yarns 52. Openings or gaps between the yarns 52 exist in other locations where one yarn 52 does not come into contact with or join another yarn 52, but joins are formed between the yarns 52 at the point of contact. The entangled and joined yarns 52 pass through the funnel outlet of the funnel 74 and enter the cooling tank 76. For convenience of reference, the combined yarns 52 are referred to as the yarn mesh structure 90.

[0031] The cooling tank 76 holds a liquid, such as water or a mixture of water and other fluids. The liquid in the cooling tank 76 helps support the intertwined filaments 52, limiting further compaction or densification of the filaments 52 to an arrangement that is not too open or too porous, thereby maintaining the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance, which may result in additional bending, curling, or looping of adjacent filaments 52 on the surface of the liquid or within the funnel 74, in order to further construct the filament mesh structure 90. The liquid also cools the filaments 52 while they are in the liquid. For example, the liquid cools the filaments 52 from the outside, causing them to solidify and preventing them from bonding in further positions. At this point, the filaments 52 are relatively hard, no longer plastic, and therefore generally, they maintain their shape and are not moldable or remold unless reheated.

[0032] The material handling subsystem 78 transports the yarn mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that help move the yarn mesh structure 90 through the liquid. In some configurations, a tractor conveyor 92 is provided inside the cooling tank 76 to help pull the yarn mesh structure 90 away from the funnel 74 and counteract the buoyancy of the yarn 52.

[0033] One or more other rollers, such as roller 94, keep the yarn mesh structure 90 submerged in the liquid and guide it through the cooling tank 76. For example, roller 94 can guide the yarn mesh structure 90 toward a conveyor belt 96 and shaker table 98 located outside the cooling tank 76. The shaker table 98 vibrates the yarn mesh structure 90 while it is on the conveyor belt 96 to remove the liquid. Alternatively, or in addition to these, the yarn mesh structure 90 may be compressed to remove the liquid, or air may be blown toward the yarn mesh structure 90 to remove the liquid, or both. It is also conceivable that the yarn mesh structure 90 may be hung to dry while wet, or dried in the air.

[0034] The manufacturing system 60 described above is a continuous flow process in which the yarn mesh structure 90 is formed as a continuous structure when the yarn extrusion is not interrupted. Further processing of the yarn mesh structure 90 is provided after it leaves the cooling tank 76, to cut the yarn mesh structure 90 into individual pieces or blanks for individual cushions. Such processing is carried out by the cutting subsystem of the manufacturing system 60. The cutting subsystem can be any suitable type. For example, the cutting system can cut the yarns 52 of the yarn mesh structure 90 into blanks using blades, knives, hot knives, saws, fluid jets, etc.

[0035] The manufacturing system 60 also includes a layer distribution subsystem 100, an example of which is shown in Figures 4 and 5. The layer distribution subsystem 100 may be part of the continuous flow process of the manufacturing system 60 and may be located downstream of the cooling tank 76, for example, after the shaker table 98. Thus, the layer distribution subsystem 100 may distribute material onto the yarn mesh structure 90 before the yarn mesh structure 90 is cut into pieces. In some embodiments, the layer distribution subsystem 100 is configured to distribute material onto pieces or blanks of the yarn mesh structure 90 that have been cut by the cutting subsystem.

[0036] The layer distribution subsystem 100 distributes layers 110 of material onto one or more sides 112 of the yarn mesh structure 90. The layers 110 can be made from any suitable material(s) or more. In some embodiments, the layers 110 are made from the same material as the yarn mesh structure 90 or the yarns 52 of the yarn mesh structure 90. By using a material common to the layers 110 and the yarn mesh structure 90, or different materials with similar melting points, the bonding of the layers 110 to the yarn mesh structure 90 can be facilitated.

[0037] Figure 6 shows an enlarged view of a portion of the yarn mesh structure 90, which has a layer 110 placed on and bonded to it. An example of bonding at the point where the layer 110 contacts the yarns 52 of the yarn mesh structure 90 is shown by reference numeral 114.

[0038] The layer distribution subsystem 100 uses a second tool 120, which is different from the first tool, i.e., the extruder 72, that extrudes the set of yarns of the yarn mesh structure 90. The second tool 120 distributes the layers 110. In some configurations, the layer distribution subsystem 100 includes a material supply unit 130 and an extruder 132, similar to the material supply unit 70 and extruder 72 described above. The layers 110 may be distributed in a molten state. In some configurations, the layer distribution subsystem 100 includes a heating device 136. The layer distribution subsystem 100 may omit a funnel and a cooling tank.

[0039] The material supply unit 130 holds the material that forms the layer 110. In some configurations, the material supply unit 130 holds the material to be extruded to form the layer 110, for example, solid beads, flakes, granules, pellets, or powder made from the material. In other configurations, the material supply unit 130 contains or holds material that is not extruded to form the layer 110. For example, the material supply unit 130 may distribute the layer 110 from a roll. In some embodiments, the layer 110 is a pre-fabricated film or thin sheet of flexible material that is distributed by unwinding the film from the roll onto a filament mesh structure 90. In such configurations, the extruder 132 may be omitted.

[0040] If provided, the extruder 132 melts the material stock and extrudes the material stock into layers 110. The extruder 132 may have a similar configuration to the extruder 72 described above and may operate in a similar manner. The layers 110 distributed by the extruder 132 consist of one or more filaments, films, or both, examples of which are discussed in more detail below. In some configurations, the extruder 132 provides molten material to a mold 134 having one or more through holes or forming openings through which the molten material passes, thereby extruding the layers 110 as films or filaments. The layers 110 fall downward onto the filament mesh structure 90 under gravity.

[0041] In some configurations, the layer distribution subsystem 100 and the second tool 120 are stationary, while the yarn mesh structure 90 moves relative to the layer distribution subsystem 100. For example, the yarn mesh structure 90 may be placed on a conveyor that moves the yarn mesh structure 90 relative to the second tool 120.

[0042] In some configurations, the layer distribution subsystem 100 and the second tool 120 move relative to the yarn mesh structure 90. For example, the second tool 120 may be positioned on a movable platform or robotic manipulator, which moves relative to the yarn mesh structure 90, thereby enabling the layers 110 to be distributed on the yarn mesh structure 90 at desired locations or in a desired pattern.

[0043] In some configurations, the layer distribution subsystem 100 is handheld or manually operated. For example, the second tool 120 may be a handheld device such as a distribution gun or extrusion welder that can distribute the layer 110 through an outlet such as a nozzle 140. The material supply unit 130 may be mounted on the second tool 120 or positioned remotely from the second tool 120. The nozzle 140 of the second tool 120 may be positioned near the side 112 of the filament mesh structure 90 to which the layer 110 is distributed. A switch or trigger on the second tool 120 may be activated to operate the second tool 120 and distribute the layer 110 from the nozzle 140. The layer 110 may be distributed as one or more filaments or films, as described above.

[0044] The heating device 136, if provided, provides thermal energy to reheat the yarn mesh structure 90. The term "reheating" is used because the yarns 52 of the yarn mesh structure 90 are preheated when the yarns 52 are looped and joined together. The heating device 136 can be any suitable type. For example, the heating device 136 may blow or direct a heating fluid such as air onto the yarn mesh structure 90, or direct electromagnetic radiation onto the yarn mesh structure 90. In some configurations, the heating device 136 reheats the yarn mesh structure 90 before the layer 110 is joined to the yarn mesh structure 90. In some configurations, the heating device 136 heats the yarns 52 to a temperature close to the melting temperature of the yarns 52, for example, 5 to 50 degrees Celsius lower than the melting temperature.

[0045] In some configurations, the heating device 136 is located upstream of the extruder 132 and heats the yarns 52 of the yarn mesh structure 90 immediately before or simultaneously with the distribution of the layer 110 onto the yarn mesh structure 90. In some configurations, the heating device 136 is located away from the second tool 120 that distributes the layer 110, as shown in Figure 4. In other configurations, the heating device 136 is equipped with the second tool 120, as represented by the dashed line in Figure 5. The heating device 136 can be thought to provide the layer 110 and heating gas through adjacent nozzles.

[0046] Referring to Figure 7, an example of a method for manufacturing a cushion is shown. The cushion is manufactured using manufacturing system 60.

[0047] In block 200, a yarn mesh structure 90 is formed. The yarn mesh structure 90 is formed by extruding yarns 52 in an extruder 72, bending, curling, or looping the yarns 52 so that each yarn 52 is in contact with and bonded to at least one other yarn 52, as described above.

[0048] In block 202, the yarn mesh structure 90 is cooled to set its shape. The yarn mesh structure 90 may be cooled with the liquid in the cooling tank 76, as described above.

[0049] In block 204, layer 110 is distributed onto the yarn mesh structure 90. Layer 110 is distributed by the layer distribution subsystem 100 as described above. Layer 110 is distributed onto one or more sides 112 of the yarn mesh structure 90 such that layer 110 is in contact with one or more yarns 52 of the yarn mesh structure 90.

[0050] In block 206, layer 110 is bonded to at least some members of the set of yarns 52 of the yarn mesh structure 90. For example, layer 110 may be in contact with the yarns 52 of the yarn mesh structure 90 and transfer heat to the yarns 52. As a result, the transferred heat partially melts the yarns 52, forming local bonds 114 that adhere or attach layer 110 to the yarns 52 at the point of contact. Regions of yarns 52 or yarns of the yarn mesh structure 90 that are not in contact with layer 110 are not melted, thereby allowing the yarn mesh structure 90 to maintain or substantially maintain its shape without generating new bonds from one yarn 52 to another or from one yarn 52 to itself.

[0051] In block 208, the layer 110 and the filament mesh structure 90 are cooled. The layer 110 and the filament mesh structure 90 may be cooled in any preferred manner. In some configurations, the layer 110 and the filament mesh structure 90 are cooled with a gas such as air. It is also intended that the layer 110 and the filament mesh structure 90 may be cooled with a liquid such as water or a mixture containing water. When the layer 110 and the filament mesh structure 90 are cooled, the bond between the layer 110 and the filament mesh structure 90 solidifies. At this point, the layer 110 and the filament 52 are no longer in a plastic state and, therefore, generally, maintain their shape under no load and are not moldable or remold unless reheated.

[0052] Here, various examples of layer 110 are described with reference to Figures 8 to 15c. In these figures, the yarn mesh structure 90 is depicted as a rectangular block with flat sides for simplification. However, it should be understood that the yarn mesh structure 90 may have a non-rectangular configuration with shaped or curved sides or side portions. Projections, recesses, or combinations thereof may be provided with one or more sides. Some examples of recesses include holes, grooves, slits, and trenches. It should also be understood that the sides 112 of the yarn mesh structure 90 are defined by portions of multiple yarns 52 arranged along a common outer region or outer boundary of the yarn mesh structure 90, and openings or voids exist along the sides between the yarns 52 where one yarn 52 does not come into contact with another yarn 52. In addition, although the sides of the yarn mesh structure 90 are indicated by reference number 112 in these figures, not all sides are referenced for clarity.

[0053] Referring to Figures 8-10, an example of layer 110 containing one or more threads is shown. The threads of layer 110 are referred to as the second set of threads to distinguish them from the set of threads 52 of the thread mesh structure 90.

[0054] In Figure 8, layer 110 includes a second set of yarns having a linear configuration. A gap 300 is provided between adjacent members of the second set of yarns. In the configuration shown, the gap 300 separates adjacent members of the second set of yarns so that the members of the second set of yarns do not come into contact with each other. It is also intended that members of the second set of yarns may come into contact with at least one other member of the second set of yarns at one or more discrete points. In such a configuration, a gap is provided between adjacent members of the second set of yarns so that one member of the second set of yarns does not come into contact with an adjacent member of the second set of yarns.

[0055] In Figure 9, layer 110 includes a second set of yarns having a non-linear configuration. The non-linear configuration may be provided by employing relative motion between the layer distribution subsystem 100 and the yarn mesh structure 90 when layer 110 is distributed. For example, the layer distribution subsystem 100 may move along a non-linear path relative to the yarn mesh structure 90, the yarn mesh structure 90 may move along a non-linear path or along multiple axes relative to the layer distribution subsystem 100, or the layer distribution subsystem 100 and the yarn mesh structure 90 may move in different directions relative to each other to provide a second set of yarns having a non-linear configuration. A gap 300 is provided between adjacent members of the second set of yarns. In the shown configuration, the gap 300 separates adjacent members of the second set of yarns so that the members of the second set of yarns do not come into contact with each other. It is also intended that members of the second set of yarns may come into contact with at least one other member of the second set of yarns at one or more discrete points. Layer 110 is intended to include yarn having linear and nonlinear segments, or a combination of linear and nonlinear yarns.

[0056] In Figure 10, layer 110 includes a continuous set of second yarns. In this configuration, each member of the second yarn set is in continuous contact with an adjacent member of the second yarn set. Such a configuration may provide layer 110 without gaps between members of the second yarn set. As a result, layer 110 may be air impermeable. Figure 10 depicts layer 110 having linear yarns. However, the yarns of layer 110 may be nonlinear, or may include nonlinear segments in one or more configurations.

[0057] In Figure 11, layer 110 comprises a film (e.g., a thin flexible material sheet) rather than individual threads. In some configurations, layer 110 containing a film is air permeable, for example, if the film has one or more pores or openings. Such configurations can allow air to pass through layer 110, which can facilitate ventilation of the cushion. For example, such a configuration may provide a ventilation sheet that allows heated or cooled air to pass through the thread mesh structure 90 and layer 110 under negative pressure (i.e., suction) or positive pressure, heating or cooling objects or occupants placed on the cushion. In some configurations, layer 110 containing a film is air impermeable. In Figure 11, layer 110 is illustrated as extending across the entire side of the thread mesh structure 90 and covering it. Thus, layer 110 extends from one edge 310 to another edge 310 of the thread mesh structure 90. In some configurations, layer 110 is located on a portion of the side surface of the yarn mesh structure 90 and extends across it. In some configurations, layer 110 extends across multiple sides of the yarn mesh structure 90 or across portions of multiple sides of the yarn mesh structure 90.

[0058] In Figure 12, layer 110 includes a film and filaments. The film of layer 110 is depicted linearly and spaced apart from the edges 310 of the side surface of the filament mesh structure 90 on which the film is placed. However, the film may extend from the edges and may have different shapes. The filaments of layer 110 are depicted in a non-linear configuration similar to that in Figure 9. However, the filaments of layer 110 may be linear, may include a combination of linear and non-linear filaments, may include continuous filaments, may include filaments that are in contact with or extend from the film of layer 110, or may include a combination thereof. Providing layer 110 as a film placed on a portion of the side surface of the filament mesh structure 90, on the entire side surface of the filament mesh structure 90, or on multiple sides of the filament mesh structure 90 may provide a surface on which barcodes or other identifying markings can be printed or applied to identify product characteristics such as manufacturing date, lot number, part number, etc. Such identification markings may be difficult to apply directly to the threads 52 of the thread mesh structure 90.

[0059] In Figure 13, layer 110 is positioned on multiple sides of the yarn mesh structure 90, rather than on all sides of the yarn mesh structure 90. The yarn mesh structure 90 has multiple sides, which may be called a set of sides. Layer 110 is positioned on two members of the set of sides of the yarn mesh structure 90 and is shown to extend across the edge 310 of the yarn mesh structure 90. Providing layer 110 on or covering the edge 310 may help to reinforce and harden the cushion where the sides of the yarn mesh structure 90 intersect or where different contours of the yarn mesh structure 90 meet.

[0060] In Figure 14, layer 110 is positioned on all sides of the yarn mesh structure 90. Thus, layer 110 may enclose the yarn mesh structure 90. In some configurations, layer 110 or a portion thereof is air-impermeable. In some configurations, such as when layer 110 is air-impermeable, at least one port 320 is provided in layer 110. The port 320 allows air to enter and exit the yarn mesh structure 90. By providing a port 320 through the air-impermeable layer 110 enclosing the yarn mesh structure 90, the air pressure inside layer 110 can be altered relative to the ambient environment. For example, air may be supplied into the yarn mesh structure 90 through the port 320 to increase the internal pressure or inflate the cushion. Air may also be supplied out of the yarn mesh structure 90 through the port 320 to decrease the internal pressure or deflate the cushion. Reducing the pressure allows layer 110 to act as a vacuum bag, and the internal pressure may be reduced to pull layer 110 more tightly against the filament mesh structure 90, which may help maintain the position of layer 110 relative to the filament mesh structure 90 and may help maintain the position of components attached to layer 110, such as trim covers. Port 320 may be closed or sealed to maintain the internal pressure after the desired internal pressure has been achieved.

[0061] The layer 110 may be distributed to multiple sides of the filament mesh structure 90 in multiple ways.

[0062] Figures 15a–15c show an example of distributing layers 110, which includes rotating the filament mesh structure 90 relative to the layer distribution subsystem 100. Only a portion of the layer distribution subsystem 100 is shown in these figures for clarity.

[0063] In Figure 15a, the yarn mesh structure 90 is shown in its initial position with the layer 110 distributed to a first side surface of the yarn mesh structure 90. The layer 110 is bonded to the first side surface of the yarn mesh structure 90 where the layer 110 contacts the yarn 52 of the yarn mesh structure 90. Once the layer 110 is distributed, the yarn mesh structure 90 is then rotated, for example, around axis 330, so that the layer 110 extends along the first side surface and optionally additional sides of the yarn mesh structure 90. This is best understood by comparing Figures 15a and 15b.

[0064] In Figure 15b, the yarn mesh structure 90 is shown rotated 90° clockwise around axis 330 from the position shown in Figure 15a. This rotation allows the layer 110 to extend along a portion of the first side as the yarn mesh structure 90 rotates, and then, once the second side aligns with and is positioned beneath the location where it is distributed by the layer distribution subsystem 100, it begins to extend across the second side of the yarn mesh structure 90. Thus, the layer 110 is distributed onto the first side, and after the layer 110 is coupled to the first side of the yarn mesh structure 90, it is distributed onto additional sides of the yarn mesh structure 90.

[0065] In Figure 15c, the yarn mesh structure 90 is shown rotated 360° counterclockwise around axis 330 from the position shown in Figure 15a, such that the layer 110 wraps around the yarn mesh structure 90 and intersects with the initial position where the layer 110 is distributed on the first side surface of the yarn mesh structure 90. If overlapping is undesirable, the distribution of the layer 110 can be stopped.

[0066] In some configurations, after the layers 110 are bonded to the filament mesh structure 90, a cooling fluid such as air can be blown onto the layers 110 to promote solidification of the bonds and help maintain the position of the layers 110 as the filament mesh structure 90 rotates. The speed at which the layers 110 are distributed and the speed at which the filament mesh structure 90 rotates may also be slow enough to allow sufficient solidification of the bonds between the layers 110 within the filament mesh structure 90 without the use of a cooling fluid blown onto the layers 110.

[0067] In some configurations, the yarn mesh structure 90 may be rotated around another axis to distribute the layers 110 along additional sides of the yarn mesh structure 90. For example, the yarn mesh structure 90, configured as a rectangular block, can be rotated around an axis perpendicular to axis 330 to distribute the layers 110 along one or more sides of the yarn mesh structure 90 on which axis 330 extends.

[0068] Item 1. A cushion having a yarn mesh structure and a layer, wherein each member of the yarn set is looped and coupled to at least one other member of the yarn set, the yarn mesh structure defines a first side, and the layer is positioned on the first side and coupled to at least some members of the yarn set.

[0069] Item 2. The cushion described in Item 1, wherein the layer includes a second set of yarns.

[0070] Item 3. The cushion according to Item 2, wherein gaps are provided between adjacent members of the second set of threads.

[0071] Item 4. The second set of yarns described above is continuous, as per the cushion in Item 2.

[0072] Item 5. The cushion described in Item 1, wherein the layer includes a film.

[0073] Item 6. The cushion described in Item 5, wherein the film is air-impermeable.

[0074] Item 7. The cushion described in any of the preceding items, wherein the layer is positioned on a portion of the first side surface.

[0075] Item 8. The layer is the cushion described in Item 7, extending from the edge of the first side surface.

[0076] Item 9. The filament mesh structure is a cushion according to any of the preceding items, wherein the first side is a member of the set of side, and the layer is provided on the first side and on at least one member of the set of side.

[0077] Item 10. The cushion according to any one of items 2, 5, or 6, and any one of items 7 through 9 as it is dependent on any one of items 2, 5, or 6, wherein the layer is air-impermeable and the layer is provided with ports that allow air to enter and exit the filament mesh structure.

[0078] Item 11. The cushion according to Item 10, wherein the filament mesh structure comprises a set of sides, the first surface being a member of the set of sides, and the layer being provided on all members of the set of sides.

[0079] Item 12. A method comprising the steps of extruding a set of yarns; forming loops with each member of the set of yarns and joining each member of the set of yarns to at least one other member of the set of yarns in order to form a yarn mesh structure; cooling the yarn mesh structure to set the shape of the yarn mesh structure; distributing layers onto a first side surface of the yarn mesh structure; and joining the layers to the first side surface.

[0080] Item 13. The method according to Item 12, wherein the step of distributing the layer includes the step of distributing the layer in a molten state.

[0081] Item 14. The method according to any one of items 12 to 13, further comprising the step of reheating the filament mesh structure before the step of joining the layers.

[0082] Item 15. The method according to any one of items 12 to 14, wherein the layer is air permeable.

[0083] Item 16. The method according to any one of Items 12 to 15, wherein the filament mesh structure and the layer are made of the same material.

[0084] Item 17. The method according to any one of Items 12 to 16, wherein the layer includes a second set of yarns bonded to the yarn mesh structure, and members of the second set of yarns are in contact with the yarn mesh structure.

[0085] Item 18. The method according to any one of items 12 to 17, wherein the step of extruding the set of yarns includes the step of extruding the set of yarns using a first tool, and the step of distributing the layers includes the step of distributing the layers using a second tool.

[0086] Item 19. The method of any one of items 12 to 18, further comprising the steps of rotating the filament mesh structure after bonding the layer to the first side surface, and distributing the layer onto a second side surface of the filament mesh structure and bonding the layer to the second side surface of the filament mesh structure.

[0087] Item 20. The method according to any one of items 12 to 19, further comprising the steps of rotating the filament mesh structure after bonding the layer to the first side surface, and distributing the layer onto further sides of the filament mesh structure and bonding the layer to the further sides of the filament mesh structure, thereby forming an air-impermeable layer around the filament mesh structure.

[0088] While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the invention. Rather, it should be understood that the terms used herein are descriptive rather than restrictive, and that various modifications can be made without departing from the spirit and scope of the invention. Furthermore, features of various embodiments can be combined to form further aspects of the invention.

Claims

[Claim 1] A set of yarns, each member of the set of yarns being a yarn mesh structure coupled to at least one other member of the set of yarns, A layer is provided which is arranged on all sides of the aforementioned filament mesh structure, coupled to at least some members of the set of filaments, and is air-impermeable. A cushion characterized by having a port disposed in the layer that allows air to enter and exit the yarn mesh structure, thereby enabling the expansion and contraction of the yarn mesh structure.

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