Retainer and assembly method for seat assemblies

Abstract

A retainer is described that includes an elongate member attached to a trim cover and a plurality of anchors extending from the elongate member. Each of the anchors has a body having a first end attached to the elongate member and a second end opposite the first end, the second end terminating in a sharp tip. Each of the anchors has a plurality of barbs, each barb extending from the body in a direction away from the tip. For each of the plurality of anchors, a cushioning material is gripped between the body and each of the barbs when the anchor is inserted into the cushion. A method of assembling a seat assembly that includes providing the retainer is also described.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 366,676, filed on June 20, 2022, and Danish Patent Application No. PA202370028, filed on January 19, 2023, the entire disclosures of both of which are incorporated herein by reference in their entirety.

[0002] This disclosure relates to a retainer, a sheet assembly having the retainer, and an assembly method.

Brief Description of the Drawings

[0003] [Figure 1] A perspective view of a non - limiting exemplary embodiment of a sheet assembly. [Figure 2A] A perspective view of a non - limiting exemplary embodiment of a retainer according to this disclosure. [Figure 2B] A perspective view of a non - limiting exemplary embodiment of a retainer according to this disclosure. [Figure 2C] A perspective view of a non - limiting exemplary embodiment of a retainer according to this disclosure. [Figure 3] A side view of a non - limiting exemplary embodiment of a retainer according to this disclosure. [Figure 4] A side view of a non - limiting exemplary embodiment of a retainer according to this disclosure inserted into a cushioning material. [Figure 5] An exemplary flowchart showing a non - limiting exemplary embodiment of the method according to this disclosure.

Best Mode for Carrying Out the Invention

[0004] Next, embodiments will be referenced in detail. Examples are shown in the accompanying drawings. In the following detailed description, numerous specific details are given in order to provide a full understanding of the various described embodiments. However, it will be obvious to those skilled in the art that various described embodiments can be carried out without these specific details. In other cases, known methods, procedures, components, features, and elements are not described in detail so as not to unnecessarily obscure the aspects of the embodiments.

[0005] It should be understood that the embodiments disclosed are illustrative only and that various alternative forms are possible. The drawings are not necessarily drawn to exact scale, and 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 employ the embodiments relating to this disclosure in various ways.

[0006] "One or more" and / or "at least one" includes the function being performed by one element, the function being performed by two or more elements, for example in a distributed manner, multiple functions being performed by one element, multiple functions being performed by multiple elements, or any combination thereof.

[0007] Furthermore, while terms such as "first," "second," etc., are used herein in some instances to describe various elements, it will be understood that these elements should not be limited by these terms. These terms are used merely to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first contact may be referred to as the second contact, and similarly, the second contact may be referred to as the 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 descriptions of the various embodiments described herein are for the purpose of describing specific embodiments only and are not intended to limit them. Where used in the descriptions of the various embodiments and in the appended claims, singular nouns ("a", "an", and "the") are intended to include plural nouns unless the context clearly indicates otherwise. Furthermore, where used herein, the terms "and / or" are intended to refer to and encompass any possible combination of one or more of the related enumerated items. In addition, where used herein, the terms "equipped with" or "containing" specify the presence of a particular feature, step, operation, element, and / or component, but are not intended to exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0009] Where used herein, the term “when” shall be interpreted, at the discretion of the context, to mean “when,” “as soon as,” “as soon as,” “as in determining,” or “as in determining.” Similarly, the phrases “when it is determined” or “when [the specified condition or event] is detected” shall be interpreted, at the discretion of the context, to mean “as soon as it is determined,” “as in determining,” “as soon as [the specified condition or event] is detected,” or “as in determining [the specified condition or event].”

[0010] Referring to Figure 1, a perspective view of a non-limiting exemplary embodiment of the seat assembly 10 is shown. The seat assembly 10 can be configured for use in a vehicle such as a passenger car or a truck. The seat assembly 10 may include a seat back 12 and a seat bottom 14. The seat back 12 may be configured to support the back of a seat occupant. The seat bottom 14 may be configured to support a seat occupant. In vehicle applications, the seat bottom 14 may be attached to a support surface such as the vehicle floor.

[0011] The seat back 12 can be pivotally rotatable around an axis 16 relative to the seat bottom 14. For example, one or more reclining chair mechanisms, pivot pins, etc., can pivotally connect the seat back 12 to the seat bottom 14. Alternatively, the seat back 12 or any part thereof does not need to be pivotally connected to the seat bottom 14. For example, the seat back 12 may be pivotally mounted to the vehicle body structure so as to be part of a bench seat configuration.

[0012] The seat back 12 may include a headrest 20 configured to support the head of the seat occupant. The headrest 20 may be positioned at the top of the seat back 12. The headrest 20 may be integrated with the seat back 12, or it may be a separate component that is adjustable and positionable relative to the top of the seat back 12.

[0013] The seat back 12 and the seat bottom 14 may each have at least one seat cushion 30. The seat back 12 and the seat bottom 14 may also each have side bolsters 32 and a central seating portion 34 of the cushion 30. As will be described in more detail later, one or more retainers can be used to secure the seat components 36 to the cushion 30.

[0014] The seat component 36 can cover the cushion 30 or be placed on top of the cushion 30. The seat component 36 can have any preferred configuration and be of any preferred type. For example, the seat component 36 may be a trim cover, trim cover material, or trim cover assembly that provides at least a portion of the visible outer surface of the seat assembly 10. The trim cover 36 may include a plurality of trim panels that can be assembled in any preferred way, such as sewing them together. The trim panels may be made of any preferred single or multiple materials, such as fabric, leather, vinyl, or a combination thereof. The seat component 36 may also be a component that is hidden by or placed under the trim cover and placed on top of the cushion 30, or alternatively such a component, such as a temperature control device like a heating pad or heating mat, an inflatable device for improving the comfort of the seat occupant or providing a massage function like a lumbar support, or a breathable material that promotes airflow for a ventilated seat.

[0015] The cushion 30 can be at least partially concealed by the sheet components 36 and can be directly or indirectly supported by the support structures of the sheet assembly 10, such as frames, panels, and support wires. The cushion 30 includes a three-dimensional mesh structure formed of randomly looped and joined filaments 60, only a few examples of the filaments 60 are illustrated in Figure 4 by randomly drawn lines for simplicity. For example, the filaments 60 may be extruded filaments made from polymer materials such as thermoplastic resins that are polyamide, polyester, polyimide, polyolefin, polypropylene, polystyrene, or combinations thereof. As one example, the filaments 60 may be made from linear low-density polyethylene (LLDPE). The extruded filaments 60 can be randomly looped, twisted, or intertwined and joined together where one filament 60 comes into contact with another filament 60, thereby obtaining a lightweight, breathable cushion with openings or voids between the filaments 60. A method for manufacturing an extruded filament mesh cushion is disclosed in U.S. Patent Application No. 17 / 555,875, filed December 20, 2021, entitled "System and Method of Making a Mesh Cushion," a copy of which is attached as Annex A. Thus, the cushion 30 does not have to be made of foam such as urethane foam, and may partially or completely replace a conventional urethane foam cushion. Alternatively, the cushion may be a conventional foam cushion such as a urethane foam cushion.

[0016] Figures 2A to 2C are perspective views of non-limiting exemplary embodiments of the retainer 40 according to the present disclosure. As can be seen in Figures 2A to 2C, and continuing with reference to Figure 1, the retainer 40 in each embodiment includes an elongated member 42 and a plurality of anchors 44. In this regard, the elongated member 42 includes a planar strip, and each of the plurality of anchors 44 is planar. However, individually or in combination, the elongated member 42 and the anchors 44 may have any other preferred configuration, or the elongated member 42 and the anchors 44 may be given any other preferred configuration.

[0017] In the embodiments shown in Figures 2A to 2C, the elongated member 42 and the plurality of anchors 44 are formed as a single unit, but alternatively, they may be individual components attached to one another. In this regard, the retainer 40 including the elongated member 42 and anchors 44 may be formed by injection molding, extrusion molding and punching, or by stamping or cutting (e.g., laser cutting) from a sheet. The elongated member 42 is also configured or provided to be attached to the trim cover 36. In this regard, the elongated member 42 may be sewn or stitched to the trim cover 36, but other known mounting means or methods may be used instead. The elongated member 42, together with the anchors 44, may also be cut to any length suitable or required for use in a particular application or environment in which the component 36 is fixed to the cushion 30, as described herein.

[0018] Each of the multiple anchors 44 extends from the elongated member 42. Each of the multiple anchors 44 has a body 46 having a first end 48 attached to the elongated member 42 and a second end 50 opposite to the first end 48. The second end 50 is terminated with a pointed tip. Each of the multiple anchors 44 has multiple barbs 52, each barb 52 extending from the body 46 in a direction away from the tip of the second end 50 of the anchor 44. For each of the multiple anchors 44, the cushion material 30 is gripped between the body 46 and each of the multiple barbs 52 when the anchor 44 is inserted into the cushion 30 (see Figure 4). In this regard, the pointed tip of the second end 50 of each anchor 44 serves to pierce or can function to pierce the cushion material 30.

[0019] It should be noted that the anchors 44, including the barbs 52 shown in Figures 2A to 2C, are merely illustrative and may generally take any shape or be given any shape. The anchor 44 shown in Figure 2A is given a shape that can be described as an inverted “Christmas tree,” and the anchor 44 shown in Figure 2C is given a shape that can be described as a “ship’s anchor.” In this regard, Figure 3 is a side view of a non-limiting exemplary embodiment of the retainer 40 according to this disclosure. More specifically, a side view of a single anchor 44 having an inverted “Christmas tree” shape from the embodiment of the retainer 40 of Figure 2A is shown.

[0020] In this regard, the size and shape of the individual anchors 44 extending from the elongated member 42 may differ. For example, the shape of the anchors 44 extending from the elongated member 42 may alternate between inverted "Christmas tree" and "ship's anchor" shapes, as shown in Figures 2A and 2C, respectively. Furthermore, although they are shown to be spaced equally along the length of the elongated member 42, the distance between adjacent anchors 44 may differ and may vary. Similarly, the number of anchors per unit length of the elongated member 42 (i.e., density) may also vary.

[0021] It should be noted that, generally speaking, the anchor 44 can take any size, or can be given any size. In this regard, an anchor 44 having a pointed tip with a steep or acute angle and a second end 50 having a smaller cross-sectional area (with respect to the cross-section crossing the body 46 of the anchor 44 in a direction parallel to the elongated member 42) requires less force to insert the anchor 44 into the cushion 30 material than an anchor 44 having a pointed tip with a larger angle and a second end 50 having a larger cross-sectional area. Therefore, the anchor 44 of the embodiment shown in Figure 2C generally requires more force to insert into the cushion 30 than the anchor 44 of the embodiments shown in Figures 2A and 2B.

[0022] It should be further noted that the number of bars 52 on each of the anchors 44 shown in Figures 2A to 2C is merely illustrative, and any number of bars 52 may be provided. Furthermore, the number of bars 52 on both sides of the anchor 44 may be different, the bars 52 on both sides of the anchor 44 do not need to be directly opposite each other (i.e., mirrored), the bars 52 along the body 46 do not need to be spaced equally apart, and each bar 52 may have a different shape, or each bar may be given a different shape. In this regard, the larger the size and / or the greater the number of bars 52 on the anchor 44, the more effective the anchor 44 is at gripping the material of the cushion 30, and the greater the resistance of the anchor 44 to detaching from or retracting from the cushion 30. Therefore, the anchor 44 in the embodiments shown in Figures 2A and 2C is more resistant to detaching from the cushion 30 than the anchor 44 in the embodiment shown in Figure 2B.

[0023] However, it should be noted that the optimal size and shape of the anchor 44 including the return 52 may be determined by the properties of the material of the cushion 30. In this regard, as described above, in the case of the cushion 30 including a three-dimensional mesh structure formed by filaments 60 randomly looped and joined of one or more extruded polymer materials, depending on the manufacturing process, a cushion 30 having a cell structure with larger or smaller materials may be obtained. As a result, the size and shape of one or more of the anchors 44 shown in FIGS. 2A-2C, or an anchor 44 having a size or shape different from that shown, may be most suitable for the material of a particular cushion 30.

[0024] FIG. 4 is another side view of a non-limiting exemplary embodiment of a retainer 40 according to the present disclosure. As seen in FIG. 4, a single anchor 44 having an inverted "Christmas tree" shape from the embodiment of the retainer 40 of FIG. 2A is shown, and the retainer 40 is partially disposed within the material of the cushion 30. More specifically, the anchor 44 of the retainer is shown in phantom lines in a state of being inserted into the material of the cushion 30, and the elongate member 42 is located on the surface of the cushion 30. As described above, the elongate member 42 of the retainer 40 can first be sewn or stitched to the trim cover 36. Thereafter, the anchor 44 of the retainer 40 is inserted into the material of the cushion 30. In this way, the trim cover 36 is thereby attached to the cushion 30.

[0025] Therefore, the retainer 40 of the present disclosure can replace a known mechanism, device, system, means or method for attaching the trim cover 36 to the cushion 30, such as a conventional polyurethane foam cushion, including clips, hog rings and wire fasteners attached to the trim cover 36 and configured to cooperate with the bead-like Duon (trademark) attachment mechanism of the cushion 30, and / or attachment mechanisms or fasteners formed or molded within the cushion 30. In this regard, it is noted that the retainer 40 of the present disclosure need not be formed or molded within the material of the cushion 30. The retainer 40 of the present disclosure also facilitates and / or enables the attachment of the trim cover 36 to a cushion 30 having no formed, provided or made single or plural recesses, such as a cushion 30 having a three-dimensional mesh structure formed by randomly looped and joined filaments 60 of one or more extruded polymer materials, as described above. However, the retainer 40 of the present disclosure is also suitable for attaching the trim cover 36 to a cushion 30 including single or plural recesses such as elongated channels, holes, depressions or grooves provided, formed or made therein to receive the plural anchors 44, and the single or plural recesses can be provided at any suitable location, for example, at the location where the side bolster 32 contacts the central seating portion 34 of the cushion 30 (see FIG. 1).

[0026] In this regard, as can be seen in Figure 4, the cushion 30 includes a three-dimensional mesh structure formed of randomly looped and joined filaments 60, only a few examples of the filaments 60 are illustrated by randomly drawn lines for simplicity. As described above, the second end 50 of the anchor 44 terminates with a pointed tip, and a plurality of barbs 52 extend from the body 46 in a direction away from the pointed tip of the anchor 44, and they serve to pierce or function to pierce the material of the cushion 30. Similarly, as described above, when the anchor 44 is inserted into the cushion 30, the material of the cushion 30 (i.e., the looped and joined filaments 60) is gripped between the body 46 and each of the plurality of barbs 52. Thus, the retainer 40 of the present disclosure provides a trim retainer designed to bite into the material of the cushion 30, such as strands or filaments of a non-foam mesh cushion or pad. The retainer 40 of this disclosure also provides a lip or a fitting with a lip that enables or facilitates the adhesion of the trim cover 36 to the cushion 30, such as strands or filaments of a non-foam mesh cushion or pad.

[0027] Referring next to Figure 5, an exemplary flowchart illustrating a non-limiting exemplary embodiment of method 70 according to the present disclosure is shown. As can be seen in Figure 5, and continuing with reference to Figures 1 to 4, method 70 for assembling a sheet assembly comprises providing a retainer 40 having an elongated member 42 and a plurality of anchors 44 extending from the elongated member 42, where each of the plurality of anchors 44 has a body 46 having a first end 48 attached to the elongated member 42 and a second end 50 opposite to the first end 48, the second end 50 terminating with a pointed tip, and each of the plurality of anchors 44 has a plurality of barbs 52, each barb 52 extending from the body 46 in a direction away from the tip. This method further includes attaching the elongated member 42 to the trim cover 36 (74) and inserting a plurality of anchors 44 into the cushion 30 (76), wherein for each of the plurality of anchors 44, the material of the cushion 30 is gripped between the plurality of barbs 52 and the main body 46.

[0028] According to the assembly method 70 of this disclosure, inserting a plurality of anchors 44 into the cushion 30 (76) may include piercing the material of the cushion 30 with the tip of each anchor 44 (78). As described above, the elongated member 42 may include a planar strip, and attaching the elongated member 42 to the trim cover 36 (74) may include sewing or stitching the elongated member 42 to the trim cover 36 (80).

[0029] Herein, according to method 70 of the present disclosure, the plurality of anchors 44 can be spaced along the elongated member 42 such that there is an equal distance between adjacent anchors 44, but alternative spacing of the anchors 44 may be provided as described above. Similarly, as described above, the elongated member 42 and the plurality of anchors 44 may be an integral member or may be formed as an integral member.

[0030] The assembly method 70 of the present disclosure may further include (82) preparing a cushion 30 which is a three-dimensional mesh structure formed of looped and joined filaments, as described above. Similarly, as described above, such filaments can be extruded to form a three-dimensional mesh structure. Furthermore, the assembly method 70 of the present disclosure facilitates and / or enables the attachment of a trim cover 36 to a cushion 30 which does not have one or more recesses formed in the cushion to receive multiple anchors 44, such as a cushion 30 which has a three-dimensional mesh structure formed of one or more randomly looped and joined filaments 60 of one or more extruded polymer materials, as described above. However, the retainer 40 of the present disclosure is also suitable for the attachment of a trim cover 36 to a cushion 30 which includes one or more recesses provided, formed, or fabricated inside.

[0031] Item 1. According to one embodiment, the present disclosure provides a retainer comprising an elongated member attached to a trim cover, and a plurality of anchors extending from the elongated member, each of which has a body having a first end attached to the elongated member and a second end opposite to the first end, the second end terminating at a pointed tip, and each of the plurality of anchors having a plurality of barbs, each barb extending from the body in a direction away from the tip, wherein for each of the plurality of anchors, a cushioning material is gripped between the body and each of the plurality of barbs when the anchor is inserted into the cushion.

[0032] Item 2. In another embodiment, the disclosure provides the retainer according to Item 1, wherein the elongated member includes a planar strip.

[0033] Item 3. In another embodiment, the Disclosure provides a retainer according to Item 1 or 2, wherein each of the multiple anchors is planar.

[0034] Item 4. In another embodiment, the Disclosure provides a retainer according to any one of Items 1 to 3, wherein an elongated member is sewn to a trim cover.

[0035] Item 5. In another embodiment, the Disclosure provides a retainer according to any one of items 1 to 4, wherein a plurality of anchors are spaced along a slender member such that adjacent anchors are spaced equally apart.

[0036] Item 6. In another embodiment, the disclosure provides a retainer according to any one of items 1 to 5, wherein a long member and a plurality of anchors are formed as a single unit.

[0037] Item 7. In another embodiment, the Disclosure provides a retainer according to any one of items 1 to 6, wherein the retainer is formed by injection molding or by stamping or cutting from a sheet.

[0038] Item 8. In another embodiment, the Disclosure provides a retainer according to any one of Items 1 to 7, wherein a pointed tip pierces a cushioning material.

[0039] Item 9. In another embodiment, the Disclosure provides a retainer according to any one of Items 1 to 8, wherein the cushioning material comprises a mesh formed from looped and joined filaments.

[0040] Item 10. In another embodiment, the present disclosure provides the retainer described in Item 9, wherein the filament is extruded to form a three-dimensional structure.

[0041] Item 11. In another embodiment, the Disclosure provides a retainer according to any one of Items 1 to 10, wherein the cushioning material does not have recesses formed to receive a plurality of anchors.

[0042] Item 12. In another embodiment, the Disclosure provides a seat assembly comprising a cushion, a trim cover, and a retainer as described in any one of items 1 to 11, for attaching the trim cover to the cushion.

[0043] Item 13. According to one embodiment, the present disclosure provides a method for assembling a seat assembly, comprising: providing a retainer having an elongated member and a plurality of anchors extending from the elongated member, each of the plurality of anchors having a body having a first end attached to the elongated member and a second end opposite to the first end, the second end terminating at a pointed tip, each of the plurality of anchors having a plurality of barbs, each barb extending from the body away from the tip; attaching the elongated member to a trim cover; and inserting the plurality of anchors into a cushion, wherein for each of the plurality of anchors, the cushion material is gripped between the plurality of barbs and the body.

[0044] Item 14. In another embodiment, the Disclosure provides the method of Item 13, wherein inserting a plurality of anchors into a cushion involves piercing the cushion material with the tip of each anchor.

[0045] Item 15. In another embodiment, the Disclosure provides the method of Item 13 or 14, wherein the elongated member includes a planar strip, and attaching the elongated member to the trim cover includes sewing the elongated member to the trim cover.

[0046] Item 16. In another embodiment, the Disclosure provides the method according to any one of Items 13 to 15, wherein a plurality of anchors are spaced along a long member such that adjacent anchors are at equal intervals from one another.

[0047] Item 17. In another embodiment, the present disclosure provides the method according to any one of items 13 to 16, wherein the elongated member and the plurality of anchors are integral members.

[0048] Item 18. In another embodiment, the present disclosure provides the method according to any one of items 13 to 17, further comprising providing a cushion which is a three-dimensional mesh structure formed of looped and joined filaments.

[0049] Item 19. In another embodiment, the present disclosure provides the method of Item 18, wherein the filament is extruded to form a three-dimensional mesh structure.

[0050] Item 20. In another embodiment, the present disclosure provides the method according to any one of items 13 to 19, wherein the cushion material does not have recesses formed to receive a plurality of anchors.

[0051] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the Disclosure. In this regard, the language used herein is descriptive rather than restrictive, and it should be understood that various modifications may be made without departing from the spirit and scope of the Disclosure. Furthermore, unless otherwise indicated as is evident from the context, various features, elements, components, methods, procedures, steps and / or functions of various implementing embodiments may be combined or utilized in any single or multiple combination to form further embodiments of the Disclosure, and / or performed in any order other than those specifically described herein. Appendix A [Document Name] Statement [Title of Invention] System and Method for Manufacturing a Mesh Cushion [Technical field]

[0050] This relates to a system and method for manufacturing mesh cushions, such as mesh cushions for seats. [Background technology]

[0051] A three-dimensional filament-linked structure manufacturing apparatus is disclosed in U.S. Patent No. 10,806,272. [Overview of the prefecture]

[0052] In at least one embodiment, a method for manufacturing a mesh cushion is provided. The method may include extruding a material through a plurality of filament-forming openings in a die plate to form a plurality of filaments. The filaments may be deposited on a first roller and a second roller. The first roller may be rotatable about a first axis and may define a first recess. The second roller may be rotatable about a second axis and may define a second recess. By rotating the first roller and the second roller, the filaments may be guided into the first and second recesses and through the gap located between the first roller and the second roller, thereby forming the filaments as a mesh cushion having a variable cross-sectional shape.

[0053] The first and second rollers can be separated from the die plate and positioned below the die plate.

[0054] The filament can be deposited while the first and second rollers are rotating.

[0055] The first recess and the second recess do not necessarily have mirror symmetry.

[0056] The first roller may include a first central portion and a first end plate. A first recess may extend from the first central portion. The first end plate may be rotatable together with the first central portion about a first axis. The first end plate may extend further from the first axis than the first central portion. The first end plate may overlap the second roller to guide the filament into the gap between the first roller and the second roller.

[0057] The second roller may include a second central portion and a second end plate. A second recess may extend from the second central portion. The second end plate may be rotatable together with the second central portion about the second axis. The second end plate may extend further from the second axis than the second central portion. The second end plate may overlap the first roller to guide the filament into the gap between the first roller and the second roller.

[0058] The first end plate of the first roller and the second end plate of the second roller overlap each other, allowing the filament to be guided into the gap between them.

[0059] At least a portion of the first roller and the second roller can be positioned above the funnel, defining a funnel opening through which the material can pass.

[0060] The filament extruded through the die plate can be supplied to a chamber partially defined by a housing extending between the die plate and the funnel. The first and second rollers can be housed at least partially within the chamber.

[0061] The environmental control subsystem can control the filament thickness by controlling the temperature and humidity of the air inside the chamber. The environmental control subsystem can be mounted in the housing. The environmental control subsystem can maintain the temperature of the air inside the chamber within a predetermined temperature range. This predetermined temperature range may be 10°F or less lower than the melting temperature of the material.

[0062] A method for manufacturing a mesh cushion may include extruding a material through multiple filament-forming openings in a die plate to form multiple filaments. The filaments can be guided into a funnel to solidify and engage. The filaments can then be deposited in a mold. The mold can be immersed at least partially in a fluid to cool and harden the filaments and form a mesh cushion.

[0063] The mold can be placed on a conveyor. The conveyor can move or lower the mold into a fluid.

[0064] The mold can be partially immersed in fluid as the filament is deposited.

[0065] The filament extruded through the die plate can be supplied to a chamber that includes a housing and extends between the die plate and the funnel.

[0066] A method for manufacturing a mesh cushion may include providing a die set comprising a first die plate and a second die plate positioned adjacent to each other. Multiple filaments can be formed by extruding material through a first set of filament-forming openings in the first die plate and through a second set of filament-forming openings in the second die plate. The relative position of the second die plate to the first die plate can be modified so that the second die plate prevents material from passing through some elements of the first set of filament-forming openings, thereby reducing the number of filaments formed by the die set. The filaments formed by the die set can be immersed in a fluid to cool and harden the filaments, thereby forming a mesh cushion.

[0067] The filament-forming openings of the second set may have fewer elements than the filament-forming openings of the first set.

[0068] The second die plate can be made movable between the first and second positions. The second die plate can allow material to pass through some of the elements of the first set of filament forming openings when the die plate is in the first and second positions.

[0069] At least one element of the second set of filament forming openings is larger than an element of the first set of filament forming openings, which allows material to flow through the elements of the first set of filament forming openings when the second die plate is in a first position and when it is in a second position.

[0070] Before immersing the filament, it can be guided into a funnel to solidify and engage.

[0071] A method for manufacturing a mesh cushion may include extruding material through multiple filament-forming openings in a die plate to form multiple filaments. The die plate may be connected to a robotic manipulator configured to move the die plate along multiple axes. The filaments may be deposited in the mold. The mold may be immersed at least partially in a fluid to cool and harden the filaments, thereby forming the filaments as a mesh cushion. The robotic manipulator may move the die plate as the filaments are deposited to vary the filament density of the mesh cushion.

[0072] The material can be extruded through multiple filament-forming openings at a substantially constant flow rate.

[0073] The robotic manipulator can move the die plate away from the mold, thereby reducing the diameter of the filament when it reaches and deposits inside the mold.

[0074] A robotic manipulator can move the die plate toward the mold, increasing the diameter of the filament when it reaches and deposits inside the mold.

[0075] The robotic manipulator can change the filament density by repeatedly moving the die plate toward the mold and then away from the mold.

[0076] The robotic manipulator can move the die plate at high speed in a horizontal plane to reduce filament density, and move it at low speed to increase filament density. [Brief description of the drawing]

[0077] [Figure 1] This is a schematic diagram of an example of a system for manufacturing mesh cushions. [Figure 2] This is a partial plan view of Figure 1, seen from below the die plate and above the rollers that can be installed in the system. [Figure 3] This is a schematic diagram of a second example of a system for manufacturing mesh cushions. [Figure 4] This is a schematic diagram of a third example of a system for manufacturing mesh cushions. [Figure 5A] This figure shows an example of filaments of different sizes. [Figure 5B] This figure shows an example of filaments of different sizes. [Figure 6A] This figure shows an example of a die plate that can be installed in any system associated with Figures 1 to 4. [Figure 6B] This figure shows an example of a die plate that can be installed in any system associated with Figures 1 to 4. [Figure 7] This is a side view showing stacked die plates. [Figure 8A] This is a plan view of the stacked die plates in the first position. [Figure 8B] This is a plan view of the stacked die plates in the second position. [Modes for carrying out the invention]

[0078] Where necessary, detailed embodiments of the present invention are disclosed herein, but it should be understood that the disclosed embodiments are merely illustrative of the present invention, which can be embodied in various alternative forms. The drawings are not necessarily drawn to exact scale, and 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 employ the present invention in various ways.

[0079] In the following description, when terms modifying absolute positions such as "front," "back," "top," "bottom," "left," and "right," or terms modifying relative positions such as "up," "down," "upper side," and "lower side," or terms modifying directions such as "horizontal" and "vertical," they refer to the orientation of the drawing. Unless otherwise specified, expressions such as "approximately," "substantially," and "about" mean within 10%, preferably within 5%.

[0080] Referring to Figure 1, an example of a system 10 for manufacturing a mesh cushion 12 is shown. This system may include an extrusion machine subsystem 20, an environmental control subsystem 22, a material handling subsystem 24, and a control subsystem 26.

[0081] The extrusion machine subsystem 20 can be configured to extrude the material 30 as a filament 32. In at least one configuration, the extrusion machine subsystem 20 may include a container 40, a feeder 42, a manifold 44, and an extrusion machine 46. The extrusion machine subsystem 20 may also include a first roller 50, a second roller 52, and a roller drive unit 54.

[0082] The container 40 can hold and store fragments of the material 30 to be extruded. For example, the container 40 can be configured as a hopper capable of holding beads, granules, flakes, pellets, or powder made from the material 30. The material 30 can be a polymer material such as polyester or polyethylene. The container 40 may be directly attached to the feeder 42, or it may be positioned at a location away from the feeder 42.

[0083] The feeder 42 can receive the material 30 from the container 40. The feeder 42 can gradually melt the material and transfer it to the manifold 44. The feeder 42 can have any preferred configuration. For example, the feeder 42 may include a barrel that can house a rotatable screw. The rotation of the screw can force the material 30 to move through the barrel, and the friction generated as the screw rotates can help heat the material 30. A heating element, such as a thermocouple, can be placed close to the barrel, and the heating element can provide thermal energy that can heat the barrel and the material 30. Optionally, the heating element may be positioned to provide a heating profile having multiple zones in which the temperature of the material 30 gradually increases as it moves through the barrel. Cooling equipment can also be provided to help maintain the temperature below a predetermined value in case of excessive heat. The material 30 can exit the feeder 42 in the form of molten plastic.

[0084] The manifold 44 can receive molten material 30 from the feeder 42 under pressure. The manifold 44 can guide the material 30 from the feeder 42 to the extruder 46.

[0085] The extruder 46 can extrude the material 30 as a filament 32. The extruder 46 can have any preferred configuration. For example, the extruder 46 may include one or more die plates 60, housings 62 and funnels 64.

[0086] One or more die plates 60 can be provided, each containing multiple filament forming openings 70. The filament forming openings 70 can be spaced apart from each other and can be small through-holes sized to create back pressure within the manifold 44 and barrel. The material 30 supplied by the manifold 44 passes through the filament forming openings 70 under pressure (i.e., is extruded from the die plate 60), thereby forming filaments 32. Filaments can be formed by each filament forming opening 70 through which the material 30 passes under pressure.

[0087] The housing 62 can receive and support the die plate 60. In addition, the housing 62 can extend between the die plate 60 and the funnel 64. The housing 62 can work in cooperation with the die plate 60 and the funnel 64 to fully or partially define the chamber 80. The chamber 80 can be positioned below the die plate 60 and above the funnel 64. Thus, the filament 32 formed by or extruded through the die plate 60 can be supplied to the chamber 80. The chamber 80 can be a sealed area that is at least partially separated or isolated from the surrounding environment. In Figures 1, 3 and 4, the side of the housing 62 closest to the viewer from the illustrated viewpoint is omitted in order to better illustrate the internal features of the housing 62. The environmental control subsystem 22 can help control the environment within the chamber 80, as will be discussed in more detail later.

[0088] If provided, the funnel 64 can be positioned close to the bottom of the housing 62. The funnel 64 can define a funnel opening 90 through which the material 30, or a mesh cushion 12 made from the material 30, can pass. The funnel opening 90 can have a width smaller than or extend over a shorter distance than the filament forming opening 70 extends along the die plate 60. Thus, the funnel opening 90 can help solidify or compress the filament 32 in one or more configurations. In at least one configuration, the funnel 64 can extend into the fluid provided in the material handling subsystem 24, which can help isolate the chamber 80 from the ambient air and the surrounding environment. In one or more configurations, it is also intended that the funnel 64 may be omitted. If the funnel 64 is omitted, it is also intended that the housing 62 can extend into the fluid in the material handling subsystem 24. In the configuration shown in Figure 1, the funnel 64 passes between the first roller 50 and the second roller 52 and receives the material 30 formed by the first roller 50 and the second roller 52.

[0089] The first roller 50 can be positioned between the die plate 60 and the funnel 64. For example, the first roller 50 can be positioned below the die plate 60 and separated from the die plate 60. At least a portion of the first roller 50 can be positioned above the funnel 64 and separated from the funnel 64. Thus, the first roller 50 can be housed at least partially within the chamber 80. The first roller 50 is rotatable about the first axis 100. In at least one configuration, as best shown in Figure 2, the first roller 50 may have a first central portion 110, at least one recess 112, one or more end plates 114, or a combination thereof.

[0090] The first central portion 110 may extend around the first axis 100 or surround the first axis 100. In at least one configuration, the first central portion 110 may be positioned at a constant or substantially constant radial distance from the first axis 100. The first central portion 110 may be positioned above the funnel 64.

[0091] At least one recess 112 may extend from the first central portion 110 toward the first axis 100. In the illustrated configuration, a single recess 112 is shown, but it is intended that there may be multiple recesses. Furthermore, the multiple recesses may be spaced apart from each other.

[0092] The first roller 50 may be provided with one or more end plates 114. In the illustrated configuration, two end plates 114 are shown positioned close to both ends of the first central portion 110. The end plates 114 can be rotatable together with the first central portion 110 around the first axis 100. In addition, the end plates 114 can extend further from the first axis 100 than the first central portion 110. The end plates 114 can help contain the filament 32 so that it does not roll off the ends of the first roller 50, and can help guide the filament 32 into the gap 116 located between the first roller 50 and the second roller 52. The size and configuration of the gap 116 can change as the first roller 50 and the second roller 52 rotate.

[0093] Referring to Figures 1 and 2, the second roller 52 can be aligned with the first roller 50 in general. Thus, the second roller 52 can be positioned between the die plate 60 and the funnel 64, positioned below the die plate 60, or spaced away from the die plate 60. At least a portion of the second roller 52 can be positioned above the funnel 64. Thus, the second roller 52 can be at least partially housed within the chamber 80. The second roller 52 is rotatable about the second axis 100'. In at least one configuration, as best shown in Figure 2, the second roller 52 may have a second central portion 110', at least one recess 112', one or more end plates 114', or a combination thereof.

[0094] The second central portion 110' may extend around or surround the second axis 100'. In at least one configuration, the second central portion 110' may be positioned at a constant or substantially constant radial distance from the second axis 100'. The second central portion 110' may be positioned above the funnel 64.

[0095] At least one recess 112' may extend from the second central portion 110' toward the second axis 100'. In the illustrated configuration, a single recess 112' is shown, but it is intended that there may be multiple recesses, and the recesses may be spaced apart from each other. In at least one configuration, the recess 112' provided on the second roller 52 may not be mirror symmetry with the corresponding recess provided on the first roller 50, thereby forming a mesh cushion with opposing sides having different configurations.

[0096] The second roller 52 may be provided with one or more end plates 114'. In the illustrated configuration, two end plates 114' are shown positioned close to both ends of the second central portion 110'. The end plates 114' can be made rotatable together with the second central portion 110' around the second axis 100'. In addition, the end plates 114' can extend further from the second axis 100' than the second central portion 110'. The end plates 114' can help contain the filament 32 so that it does not roll off the ends of the second roller 52 and can help guide the filament 32 into the gap 116.

[0097] An end plate 114 provided on the first roller 50 can engage with an adjacent end plate 114' provided on the second roller 52, and can overlap with the end plate 114' to help guide the filament 32 into the gap 116. In addition, the end plates can overlap with rollers to which no end plates are attached. For example, an end plate 114 provided on the first roller 50 can overlap with the second roller 52 to help guide the filament into the gap 116. In addition or alternatively, an end plate 114 provided on the first roller 50 may have an outer circumference or outer surface facing away from the first axis 100, such that the second central portion 110' is positioned closer to the second axis 100' than the second axis 100' is positioned relative to the second axis 100'. The end plate 114' provided on the second roller 52 may have an outer circumference or outer surface facing away from the second axis 100', positioned closer to the first axis 100 than the first central portion 110 is positioned relative to the first axis 100. The end plates 114, 114' may be received inside the funnel 64 or positioned outside the funnel 64. The outer circumference or outer surface of the end plates 114, 114' may or may not be positioned above the funnel 64.

[0098] The roller drive unit 54 can be configured to rotate the first roller 50 and the second roller 52. For example, the roller drive unit 54 can rotate the first roller 50 and the second roller 52 in opposite directions around their respective axes. In Figure 1, as shown by the curved arrows, the first roller 50 can be rotated clockwise around the first axis 100 from the illustrated viewpoint, while the second roller 52 can be rotated counterclockwise around the second axis 100' from the illustrated viewpoint. In addition, the roller drive unit 54 can synchronize the rotation of the first roller 50 and the second roller 52 so that the recess 112 of the first roller 50 aligns with the recess 112' of the second roller 52 during each roller rotation, thereby forming the mesh cushion 12 so that both sides have the desired cross-section at each point along its length. If the roller synchronization is improper, the position of the recesses may be misaligned, potentially resulting in an improperly formed mesh cushion 12.

[0099] It should be noted that in various extrusion molding machine subassembly configurations, such as those shown in Figures 3 and 4, the first roller 50, the second roller 52, and the roller drive unit 54 may be omitted.

[0100] The filaments 32 can be deposited on the first roller 50 and the second roller 52 while the first roller 50 and the second roller 52 are rotating. The rotation of the first roller 50 and the second roller 52 can guide the filaments 32 toward and through the gap 116, thereby compacting the filaments 32 and bringing each filament 32 into contact with one or more other filaments 32. The filaments 32 may bend or twist in an irregular manner, generally in a non-patterned or non-repeating manner. The recesses 112, 112' can further form the filaments 32 such that the filaments 32 in contact with the surface of each roller defining the corresponding recesses 112, 112' form the undulating outer surface of that portion. Thus, since the cross-sectional area of ​​each roller is varied by the presence and configuration of the corresponding recesses 112, 112', the first roller 50 and the second roller 52 can form the filaments 32 as a mesh cushion 12 with a variable cross-sectional shape.

[0101] Referring to Figure 1, the environmental control subsystem 22 can control one or more attributes or characteristics of the air inside the chamber 80. For example, the environmental control subsystem 22 can control the temperature of the air inside the chamber 80, the humidity of the air inside the chamber 80, the airflow inside the chamber 80, the recirculation of the air inside the chamber 80, the exhaust of air from the chamber 80, or a combination thereof, to help control the thickness of the filament 32. In at least one configuration, the environmental control subsystem 22 may include a fan 120 and one or more temperature changers.

[0102] Figures 1, 3, and 4 show two temperature changers 122 and 124, but it is intended that a different number of temperature changers may be provided. The temperature changers can have any preferred configuration. For example, the temperature changers can be configured as heat exchangers, heating elements, cooling elements, etc. As one example, the first temperature changer 122 may be configured to heat the air, while the second temperature changer 124 may be configured to cool and / or dehumidify the air that is circulated by the fan 120 from the chamber 80 through the environmental control subsystem 22 and returned to the chamber 80.

[0103] The environmental control subsystem 22 can be used to maintain the temperature of the air in the chamber 80 within a predetermined temperature range. This predetermined temperature range may be slightly lower than the melting temperature of the material 30. For example, the predetermined temperature range may be 10°F or less lower than the melting temperature of the material 30. Similarly, the environmental control subsystem 22 can be used to maintain the humidity of the air in the chamber 80 within a predetermined humidity range.

[0104] The components of the environmental control subsystem 22, such as the fan 120 and temperature changers 122 and 124, may be mounted on the housing 62, or they may be positioned remotely from the extrusion molding machine subsystem 20 and fluidly connected to the chamber 80 by any suitable conduit such as a hose or duct.

[0105] The material handling subsystem 24 can receive the material 30 after it has left the extrusion machine subsystem 20. The material handling subsystem 24 can be provided in various configurations. In the configuration shown in Figure 1, the material handling subsystem 24 includes a tank 130 and a conveyor 132.

[0106] Tank 130 can receive material 30 coming out of the extrusion molding machine subsystem 20. In addition, tank 130 can contain a fluid 134 such as water. The fluid 134 can be supplied in liquid form and at a temperature significantly lower than the melting temperature of the material 30. Thus, the fluid 134 can cool and harden the filament 32 to form the mesh cushion 12. Thus, the fluid 134 can cool the filament 32 so that it is no longer in a sticky molten state.

[0107] The conveyor 132 can transport the mesh cushion 12. In at least one configuration, the conveyor 132 or a portion thereof can be housed in the tank 130 and at least partially immersed in the fluid 134. The length of the conveyor 132 placed in the fluid 134 can be sufficient to provide adequate cooling and curing of the filament 32 for subsequent material handling operations.

[0108] In the configuration shown in Figure 1, a portion of the conveyor 132 is shown, located below the extrusion machine subsystem 20 and immersed in the fluid 134. The conveyor 132 can be spaced away from the extrusion machine subsystem 20 and the funnel 64 so that there is sufficient space for the filament 32 to exit the funnel 64. The conveyor 132 may be positioned closer to the surface of the fluid 134 than shown. Furthermore, it is intended that a portion of the conveyor 132 can exit the fluid 134 to facilitate the removal of the mesh cushion 12 from the tank 130.

[0109] In the configuration shown in Figure 3, the material handling subsystem 24 may also include at least one mold 140. The mold 140 may be positionable on a belt of a conveyor 132, and the conveyor 132 may be configured to move the mold 140 relative to the extrusion machine subsystem 20. The mold 140 may define a mold cavity 142 into which filaments 32 can be deposited or ejected. The mold cavity 142 may open upward or toward the extrusion machine subsystem 20.

[0110] The mold 140 may or may not be positioned within the tank 130 when the filament 32 is deposited into the mold cavity 142. Figures 3 and 4 show an example in which the mold 140 is partially contained in the fluid 134 when the filament 32 is deposited into the mold cavity 142. In a configuration in which the extrusion machine subsystem 20 is stationary, the conveyor 132 can advance the mold 140 under the funnel 64, relative to the funnel 64, thereby filling the mold cavity 142 with the filament 32. The mold 140 can then be lowered into the fluid 134.

[0111] The mold 140 can be lowered into the fluid 134 or at least partially immersed in it in various ways. In the illustrated configuration, the conveyor 132 is configured to lower the mold 140 into the fluid 134. The conveyor 132 is inclined downwards from the tank 130, so that as the mold 140 moves away from the funnel 64, the mold 140 is lowered into the fluid 134, thereby causing the fluid 134 to circulate through the filament 32 and the mold cavity 142, cooling and curing the filament 32. As an alternative example, the mold 140 can be lowered into or lifted from the fluid 134 without using the conveyor 132, for example, by moving the mold 140 generally vertically or in a rotating loop that can enter and exit the fluid 134. It is also intended that the conveyor 132 may be omitted, or the mold 140 may be moved manually or by other means, such as during small-batch production.

[0112] In the configuration shown in Figure 4, the material handling subsystem 24 can be the same as or identical to that shown in Figure 3. However, in Figure 4, the extrusion machine subsystem 20 is attached to or connected to the robot manipulator 150.

[0113] The robot manipulator 150 can be made movable along multiple axes and can have multiple degrees of freedom. For example, the robot manipulator 150 can be configured to move the extrusion molding machine subsystem 20 along a first axis 152, a second axis 154, and a third axis 156.

[0114] The first axis 152 can be a vertical axis.

[0115] The second axis 154 can be positioned perpendicular to the first axis 152 and can be a horizontal axis that extends left and right when viewed from the illustrated viewpoint.

[0116] The third axis 156 can be positioned perpendicular to the first axis 152 and the second axis 154, and can extend in the front-rear direction when viewed from the illustrated viewpoint.

[0117] The extrusion molding machine subsystem 20 can deposit the filament 32 into the mold cavity 142 when the mold 140 is stationary or in motion. It is also intended that the conveyor 132 may be omitted during small-batch production, or that the mold 140 may be moved manually or by other means. The configuration shown in Figure 4 and its related attributes will be discussed in more detail later.

[0118] Referring to Figure 1, the control subsystem 26 can monitor and control the operation of system 10. For example, the control subsystem 26 may include one or more control modules or electronic controllers 200 that can monitor and / or control the operation of one or more subsystems of system 10. For example, the controller 200 may be a microprocessor-based controller that can be electrically connected to or communicate with components of the extrusion machine subsystem 20, such as the feeder 42 and roller drive unit 54, the environmental control subsystem 22, the material handling subsystem 24, or a combination thereof. The controller 200 may also control the operation of a robot manipulator 150, if one is provided. For simplicity, a single controller is shown in Figure 1, but it is intended that the control subsystem 26 may include multiple control modules or controllers, or a distributed control architecture. The control subsystem 26 is also provided in the configurations shown in Figures 3 and 4, but is omitted from these figures simply for clarity.

[0119] The controller 200 can also process input signals or data from various input devices or sensors. Input devices that can be provided in the system 10 may include a temperature sensor 160 and a humidity sensor 162.

[0120] The temperature sensor 160 can provide a signal indicating the temperature of the air inside the chamber 80. The temperature sensor 160 can be any suitable type, such as a thermistor, thermocouple, semiconductor-based temperature sensor, or infrared sensor. The temperature sensor 160 can be installed in any suitable location. For example, the temperature sensor 160 may be installed inside the chamber 80 or in the environmental control subsystem 22.

[0121] The humidity sensor 162 can provide a signal indicating the humidity of the air inside the chamber 80. The humidity sensor 162 can be any suitable type, such as a capacitive humidity sensor, a resistive humidity sensor, or a thermal conduction humidity sensor. The humidity sensor 162 can be installed in any suitable location. For example, the humidity sensor 162 may be installed inside the chamber 80 or in the environmental control subsystem 22.

[0122] Referring again to Figure 4, the robotic manipulator 150 can be configured to move the extruder subsystem 20 to change the filament density of the mesh cushion 12. For example, the material 30 can be extruded at a substantially constant flow rate through the filament forming openings 70 of one or more die plates 60. Thus, it can be expected that the filaments 32 will have substantially the same diameter or thickness if the filament forming opening size is constant. However, the filaments 32 become thinner as the distance from the die plate 60 and the filament forming openings 70 increases. This is best understood by referring to Figures 5A and 5B.

[0123] Figure 5A shows an enlarged view of a portion of the die plate 60 and the filament formation opening 70. The die plate 60 is positioned at a first distance Z1 above the surface S.

[0124] In Figure 5B, the die plate 60 is positioned at a second distance Z2 above the surface S, where Z1 is smaller than Z2. The filament 32 extends over the increased distance and becomes thinner as the material 30 is in a molten, uncured state, so in Figure 5B, it has a thinner or smaller diameter on the surface S. These properties can be used to change the filament density of the mesh cushion 12. For example, the robotic manipulator 150 can move the die plate 60 upward or away from the mold 140 to reduce the size, thickness, or diameter of the filament 32 when deposited in the mold 140. Conversely, the robotic manipulator 150 can move the die plate 60 toward the mold 140 to increase the size, thickness, or diameter of the filament 32 when deposited in the mold 140.

[0125] The robotic manipulator 150 can also change the filament density in other ways by moving the die plate 60 while depositing the filament 32. For example, the robotic manipulator 150 can increase the filament density by repeatedly moving the die plate 60 toward and away from the mold 140, and / or by decreasing its movement speed, and / or by increasing its stationary dwell time. As another example, the robotic manipulator 150 can decrease the filament density by moving the die plate 60 faster in the horizontal plane (i.e., along the second axis 154 and / or the third axis 156) or by shortening the time spent in a particular area. Conversely, the robotic manipulator 150 can increase the filament density by moving the die plate 60 slower in the horizontal plane or by lengthening the time spent in a particular area. Therefore, filament density increases as the time spent in a particular area increases, thereby allowing more filaments to be deposited, and filament density can be decreased as the time spent in a particular area decreases.

[0126] It should also be noted that in Figure 4, various components of the environmental control subsystem 22 and the extrusion machine subsystem 20 may be omitted, such as the portion of the housing 62 located below the die plate 60, the funnel 64, or both.

[0127] Here, with reference to Figures 6A to 8B, we will consider an example of an extrusion molding machine subsystem configuration having interchangeable die plates or multiple die plates. The multiple die plates can be any of the extrusion molding machine subsystem configurations discussed earlier, such as the configurations shown in Figures 1, 3, and 4.

[0128] Figures 6A and 6B show examples of two different die plates. Die plates 60 and 60' have the same size and shape, but do not have the same number of filament forming openings 70. Die plate 60 in Figure 6A has more filament forming openings 70 than die plate 60' in Figure 6B. Therefore, the number of filaments 32 that can be provided by die plate 60 in Figure 6A is greater than the number of filaments 32 that can be provided by die plate 60' in Figure 6B. Thus, given a constant material flow rate and extrusion time, using die plate 60' in Figure 6B can provide a mesh cushion 12 with a lower filament density compared to die plate 60 in Figure 6A.

[0129] Referring to Figure 7, a configuration with two stacked die plates is shown. It should be noted that, initially, it is intended that three or more die plates may be provided in a stacked arrangement.

[0130] The configuration in Figure 7 will be examined primarily in the case of the first and second die plates stacked directly on top of each other. For clarity, the lower die plate will be referred to as the first die plate, and the die plate placed on top of the first die plate will be referred to as the second die plate. However, it is intended that the positioning of the first and second die plates may be changed or reversed, or additional die plates may be provided.

[0131] As an example, the first die plate 60 can be configured as shown in Figure 6A. The first die plate 60 may have a first set of filament forming openings 70. In at least one configuration, the elements of the first set of filament forming openings 70 can be given the same configuration.

[0132] Referring to Figures 7 and 8A, an example of a second die plate 260 is shown. The second die plate 260 can be positioned adjacent to the first die plate 60 and may have a second set of filament forming openings 270. The elements of the second set of filament forming openings 270 may or may not have the same configuration. For example, in Figure 8A, the elements of the second set of filament forming openings 270 do not necessarily all have the same configuration. Instead, some filament forming openings 270 may have the same configuration as the filament forming openings 70 of the first die plate 60 (represented as circles in Figure 8A), and some filament forming openings 270 may be larger than the filament forming openings 70 of the first die plate 60 (represented as elongated elliptical slots, Figure 8A). It is also intended that the second set of filament forming openings 270 may have fewer elements than the first set of filament forming openings 70.

[0133] The relative positioning of the second die plate 260 with respect to the first die plate 60 can be adjusted to change the alignment of the filament forming openings 70, 270 relative to each other. The change in alignment can be achieved by moving the first die plate 60 or a portion thereof relative to the second die plate 260, by moving the second die plate 260 or a portion thereof relative to the first die plate 60, or both. For example, the first die plate 60 can be held in a stationary position, and the second die plate 260 can be slid or moved along the first die plate 60 so that the second die plate 260 closes the filament forming openings 70 and at least a portion of the first die plate 60. This is best understood by comparing Figures 8A and 8B.

[0134] In Figure 8A, the second die plate 260 is shown in an example where it is in the first position. In this example, when the second die plate 260 is in the first position, it does not block any of the filament forming openings 70 of the first die plate 60. Thus, the material 30 can be extruded through the second set of filament forming openings 270 and then through the corresponding elements of the first set of filament forming openings 70 which are aligned with the elements of the second set of filament forming openings 270 to form the filaments 32.

[0135] In Figure 8B, the relative positioning of the first die plate 60 and the second die plate 260 has been changed compared to Figure 8A. In the example of Figure 8B, the first die plate 60 remains in the same position as in Figure 8A, while the second die plate 260 has moved to a second position different from the first position. As a result, some of the elements of the second set of filament forming openings 270 remain aligned with the corresponding elements of the first set of filament forming openings 70, while other elements of the second set of filament forming openings 270 are no longer aligned with the elements of the first set of filament forming openings 70. Thus, the second die plate 260 is positioned to prevent material from reaching and passing through the elements of the first set of filament forming openings 70.

[0136] More specifically, in the illustrated example, the elements of the second set of circular filament forming openings 270 are no longer aligned with any of the elements of the first set of filament forming openings 70, whereas the elongated elliptical elements of the second set of filament forming openings 270, although repositioned, are still sufficiently aligned with the corresponding elements of the first set of filament forming openings 70, allowing the material 30 to be extruded through the aligned filament forming openings 70. Thus, the larger elements of the second set of filament forming openings 270 (i.e., the elliptical elements) can allow the material 30 to flow through the corresponding elements of the first set of filament forming openings 70 when the second die plate 260 is in the first and second positions. As a result, filaments 32 are extruded when the second die plate 260 is in the first and second positions, but the number of filaments 32 formed by the die set is reduced when the second die plate 260 is in the second position.

[0137] It is intended that the die plate may move in a manner different from that described above. As one example, the die plate may be divided into multiple parts that can be moved independently. For example, the second die plate 260 may be divided in half, and each half of the second die plate 260 may be movable to selectively block or allow the flow of material 30 through a subset of the filament forming openings 70 of the first set.

[0138] As another example, the die plate may not be movable in a linear direction, but rather rotatable around an axis.

[0139] As another example, multiple die plate regions may be integrated into a single plate that can rotate around an axis. Each die plate region may have a different pattern of filament-forming openings. The single plate can then be rotated around an axis to align a particular die plate region with another die plate. As a result, each die plate region can provide a different number of filaments when positioned adjacent to or aligned with another die plate.

[0140] The second die plate 260 may be movable to a position that blocks all elements of the first set of filament forming openings 70 of the first die plate 60, thereby intending to terminate the flow of material through the die plate and end the extrusion of the filament 32.

[0141] While exemplary embodiments have been described above, these embodiments are not intended to represent all possible forms of the present invention. In this regard, the language used herein is descriptive rather than restrictive, and it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. In addition, features of various embodiments can be combined to form further embodiments of the present invention. [Document Title] Claims [Claim 1] A method for manufacturing a mesh cushion, The process involves extruding material through multiple filament-forming openings in a die plate to form multiple filaments, The method involves depositing the filament onto a first roller and a second roller, wherein the first roller is rotatable about a first axis and defines a first recess, and the second roller is rotatable about a second axis and defines a second recess. The first roller and the second roller are rotated to guide the filament into the first recess and the second recess, and through the gap between the first roller and the second roller, thereby forming the filament as the mesh cushion having a variable cross-sectional shape. Methods that include... [Claim 2] The method according to claim 1, wherein the first roller and the second roller are spaced apart from the die plate and positioned below the die plate. [Claim 3] The method according to claim 1, wherein the filament is deposited while the first roller and the second roller are rotating. [Claim 4] The method according to claim 1, wherein the first recess and the second recess do not have mirror symmetry. [Claim 5] The method according to claim 1, wherein the first roller includes a first central portion which is the starting point from which the first recess extends, and a first end plate which is rotatable together with the first central portion about the first axis and extends further from the first axis than the first central portion, the first end plate overlapping the second roller to guide the filament into the gap between the first roller and the second roller. [Claim 6] The method according to claim 5, wherein the second roller includes a second central portion which is the starting point from which the second recess extends, and a second end plate which is rotatable together with the second central portion about the second axis and extends further from the second axis than the second central portion, the second end plate overlapping the first roller to guide the filament into the gap between the first roller and the second roller. [Claim 7] The method according to claim 6, wherein the first end plate of the first roller and the second end plate of the second roller overlap each other to guide the filament into the gap between the first roller and the second roller. [Claim 8] The method according to claim 1, wherein at least a portion of the first roller and the second roller is positioned above a funnel that defines a funnel opening through which the material passes. [Claim 9] The method according to claim 8, wherein the filament extruded through the die plate is supplied to a chamber partially defined by a housing extending between the die plate and the funnel. [Claim 10] The method according to claim 9, wherein the first roller and the second roller are at least partially housed within the chamber. [Claim 11] The method according to claim 9, wherein an environmental control subsystem controls the temperature and humidity of the air in the chamber to control the thickness of the filament. [Claim 12] A method for manufacturing a mesh cushion, The process involves extruding material through multiple filament-forming openings in a die plate to form multiple filaments, The filament is guided into the funnel and the filament is solidified and engaged, The aforementioned filaments are deposited inside the mold, The mold is immersed at least partially in the fluid to cool and harden the filament and form the mesh cushion, Methods that include... [Claim 13] The method according to claim 12, wherein the mold is placed on a conveyor, and the conveyor moves the mold into the fluid. [Claim 14] The method according to claim 12, wherein the mold is partially contained in the fluid when the filament is deposited. [Claim 15] The method according to claim 12, wherein the filament extruded through the die plate is supplied to a chamber including a housing extending between the die plate and the funnel. [Claim 16] A method for manufacturing a mesh cushion, The process involves extruding material through multiple filament-forming openings in a die plate to form multiple filaments, wherein the die plate is connected to a robotic manipulator configured to move the die plate along multiple axes. The aforementioned filaments are deposited inside the mold, The process involves immersing the mold at least partially in a fluid to cool and harden the filament, thereby forming the filament as the mesh cushion, wherein the robotic manipulator moves the die plate when depositing the filament to change the filament density of the mesh cushion. Methods that include... [Claim 17] The method according to claim 16, wherein the material is extruded through the plurality of filament-forming openings at a substantially constant flow rate. [Claim 18] The method according to claim 16, wherein the robotic manipulator moves the die plate away from the mold to reduce the diameter of the filament when it is deposited in the mold. [Claim 19] The method according to claim 16, wherein the robotic manipulator moves the die plate toward the mold to increase the diameter of the filament when it is deposited in the mold. [Claim 20] The method according to claim 16, wherein the robotic manipulator moves the die plate at high speed in a horizontal plane to reduce the filament density and moves it at low speed to increase the filament density. [Document Name] Abstract [summary] A method for manufacturing a mesh cushion. This method involves extruding a material through multiple filament-forming openings in at least one die plate to form multiple filaments. The filaments can be at least partially immersed in a fluid to cool and harden them, thereby forming a mesh cushion. [Figure 1] JPEG0007838128000001.jpg178130 [Figure 2] JPEG0007838128000002.jpg146131 [Figure 3] JPEG0007838128000003.jpg200131 [Figure 4] JPEG0007838128000004.jpg168140 [Figure 5A] JPEG0007838128000005.jpg12380 [Figure 5B] JPEG0007838128000006.jpg16377 [Figure 6A] JPEG0007838128000007.jpg66168 [Figure 6B] JPEG0007838128000008.jpg72168 [Figure 7] JPEG0007838128000009.jpg73149 [Figure 8A] JPEG0007838128000010.jpg91143 [Figure 8B] JPEG0007838128000011.jpg115131

Claims

1. An elongated member that can be attached to a cover, comprising an elongated member including a planar strip, A plurality of anchors extending from the elongated member, each of the plurality of anchors being planar and oriented in the same plane as the planar strip, each of the plurality of anchors having a body with a first end attached to the elongated member and a second end opposite to the first end, the second end being terminated with a pointed tip, and each of the plurality of anchors having a plurality of barbs, each barb extending from the body in a direction away from the tip, Equipped with, A retainer wherein, for each of the plurality of anchors, the material of the mesh structure is gripped between the main body and each of the plurality of bars when the anchor is inserted into the mesh structure.

2. The retainer according to claim 1, wherein the elongated member is sewn to the cover.

3. The retainer according to claim 1, wherein the plurality of anchors are spaced apart along the elongated member such that there is an equal distance between adjacent anchors.

4. The retainer according to claim 1, wherein the elongated member and the plurality of anchors are formed as an integral member.

5. The retainer according to claim 1, wherein the retainer is formed by injection molding or by stamping or cutting from a sheet.

6. The retainer according to claim 1, wherein the pointed tip pierces the mesh structure.

7. The retainer according to claim 1, wherein the mesh structure includes a mesh formed from looped and joined filaments.

8. The retainer according to claim 7, wherein the filament is extruded to form a three-dimensional structure.

9. The retainer according to claim 1, wherein the mesh structure does not have recesses formed to receive the plurality of anchors.

10. Mesh structure and The cover and, A retainer according to any one of claims 1 to 9, comprising a retainer for attaching the cover to the mesh structure, A seat assembly equipped with this feature.

11. A retainer comprising a long member including a planar strip and a plurality of anchors extending from the long member, wherein each of the plurality of anchors is planar and oriented in the same plane as the planar strip, each of the plurality of anchors has a body having a first end attached to the long member and a second end opposite to the first end, the second end terminates with a pointed tip, and each of the plurality of anchors has a plurality of barbs, each barb extending from the body in a direction away from the tip, The aforementioned elongated member is attached to the cover, A method comprising inserting the plurality of anchors into a mesh structure, wherein, for each of the plurality of anchors, the mesh structure is gripped between the plurality of barbs and the main body.

12. The method according to claim 11, wherein inserting the plurality of anchors into the mesh structure includes piercing the material of the mesh structure with the tip of each anchor.

13. The method according to claim 11, wherein attaching the elongated member to the cover includes sewing the elongated member to the cover.

14. The method according to claim 11, wherein the plurality of anchors are spaced apart along the elongated member such that there is an equal distance between adjacent anchors.

15. The method according to claim 11, wherein the elongated member and the plurality of anchors are an integral member.

16. The method according to claim 11, further comprising preparing the mesh structure which includes a three-dimensional mesh structure formed of looped and joined filaments.

17. The method according to claim 16, wherein the filament is extruded to form the three-dimensional mesh structure.

18. The method according to claim 11, wherein the mesh structure does not have recesses formed to receive the plurality of anchors.

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