Method for manufacturing extruded mesh for vehicle seats and the resulting product

Abstract

To provide a body for a seat assembly and a method for a seat pad.SOLUTION: A body is composed of a plurality of extruded polymer filaments randomly oriented and bonded together to form a three-dimensional mesh structure. The body is elongated in an extrusion, or longitudinal, direction. First zones of the extruded polymer filaments having a first density and second zones of the extruded polymer filaments having a second density less than the first density. The first and second zones are separated by boundaries, or transition areas. There is provided a method of making a seat pad with extruded polymer filaments having different zones with different densities and hardness characteristics by controlling speed of a plurality of tractor belts in a cooling bath.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] (Cross - reference to related applications) This application claims priority to U.S. Patent Application No. 18 / 962,730, filed on November 27, 2024, and also claims the benefit of U.S. Provisional Application No. 63 / 612,215, filed on December 19, 2023. Further, this application claims priority to Danish Patent Application No. PA202470196, filed on July 18, 2024. These disclosures are hereby incorporated by reference in their entirety into this specification.

[0002] Relates to an extrudate of polymeric filaments made according to a method of forming pads having different densities across the width of the extrudate.

Summary of the Invention

Means for Solving the Problems

[0003] According to one aspect of the present invention, there is provided an article comprising a body of a plurality of extruded polymeric filaments that are randomly oriented and bonded to each other to form a three - dimensional mesh structure, the body including a first zone including the extruded polymeric filaments that are elongated in the longitudinal direction and have a first density, and a second zone including the extruded polymeric filaments having a second density lower than the first density.

[0004] According to another aspect of the present invention, there is provided a seat assembly comprising a seat frame, a seat cover, and a body including a plurality of extruded polymeric filaments that are randomly oriented and bonded to each other to form an intermediate preform, the intermediate preform including a first zone of the extruded polymeric filaments having a first density and a second zone of the extruded polymeric filaments having a second density lower than the first density, and the intermediate preform being shaped to form a molded seat cushion.

[0005] Another aspect of the present invention provides a method comprising: melting a polymer resin to form a molten polymer; extruding the molten polymer through a die head to form an extruded polymer filament; shaping and joining the extruded polymer filament into a strip of filament having a predetermined cross-section; and drawing the strip of filament longitudinally into a cooling tank using a plurality of tractor belts arranged transversely to the longitudinal direction, wherein each tractor belt draws in the strip of filament, moving one of the plurality of portions of the strip of filament longitudinally; and controlling the plurality of tractor belts to move one of the plurality of portions of the strip of filament at a different speed than the other tractor belts, thereby locally controlling the density of the plurality of portions of the strip of filament across the width of the strip of polymer filament. [Brief explanation of the drawing]

[0006] [Figure 1] This is a schematic diagram of a plastic extrusion line. [Figure 2] This is a front view of a variable-speed tractor section having multiple tractor belts arranged perpendicular to the extrusion direction and across the extrusion. [Figure 3] This is a front view of the seat back cushion. [Figure 4] This is a plan view of a seat cushion. [Figure 5] This is a cross-sectional view of the extruded preform. [Figure 6] This is a perspective view of a vehicle seat, showing the frame and seat cover partially cut away. [Modes for carrying out the invention]

[0007] Herein, embodiments are referred to in detail. Examples of embodiments are 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.

[0008] It should be understood that the disclosed embodiments are merely illustrative and that various alternative forms are possible. The figures are not necessarily to a fixed 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 provided herein in various ways.

[0009] "One or more" includes a function performed by one element, a function performed by two or more 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.

[0010] While terms such as "first," "second," etc., are used herein in some examples to describe various elements, 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 called a second contact, and similarly, a second contact may be called a first contact. Both the first and second contacts are contacts, but they are not the same contact.

[0011] The terms used in the description of the various embodiments described herein are intended to describe only specific embodiments and are not intended to limit them. When used in the description of the various embodiments described and in the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural form unless the context explicitly indicates otherwise. The terms “and / or” as used herein will be understood to refer to and include any possible combination of one or more of the enumerated items relating to the description. The terms “includes,” “including,” “comprises,” and / or “comprising,” when used herein, specify the presence of the described features, integers, steps, actions, elements, and / or components, but will not be understood to exclude the presence or addition of one or more other features, integers, steps, actions, elements, components, and / or groups thereof.

[0012] Referring to Figure 1, polymer filaments 20 Preform strips 38 An extrusion line 10 for forming the resin beads is schematically shown. The extruder 12 receives the resin beads 16 from the resin hopper 14, the resin beads 16 are melted in the extruder 12, and then die head 18 It is supplied to the die head. 18 polymer filaments 20 extrude, then form a funnel 22 Supplied through. Molded funnel 22 polymer filaments 20 to cooling tank 24 Deposit inside. Polymer filament 20 The tractor section is controlled at a manageable speed. 26 by cooling tank 24 Pulled inward. Preform strip 38 is a cooling tank 24 When pulled inward, polymer filaments 20 First, the cooling tank 24It is cooled by the water inside, so it is welded to each other. Cooling tank 24 The roller inside 28 further cools the preform strip 38 by drawing it into another cooling tank 24 . Shaker table 30 vibrates the preform strip 38 to remove water from the preform strip 38 . While the unload conveyor 32 lowers the preform strip 24 from the cooling tank 38 . The water return tank 34 collects water when the water is discharged from the preform strip 38 . The blower 36 is directed onto the water return tank 24 to cool the water when the water returns to the cooling tank 34 .

[0013] The polymer filament 20 is welded, glued, or melted and includes strands, fibers, or strips reformed into a three-dimensional mesh structure 38 . The preform strip 38 includes an intermediate preform for manufacturing a plurality of vehicle seat pads that are later cut into individual sheet pads and formed into a predetermined shape

[0014] The polymer resin 16 is supplied to the resin hopper 14 in the form of resin beads or pulverized polymer resin and includes LLDPE or HDPE

[0015] The cooling tank 24 is filled with water or a cooling aqueous solution for the polymer

[0016] The tractor section 26 described in more detail below 20 is in the longitudinal direction, which is the extrusion direction in which the polymer strand 18 flows from the die head 22 and the forming funnel20 Pull.

[0017] Referring to Figure 2, the tractor section shown in Figure 1 26 The diagram shows a plurality of tractor belts 40a-40e that are controlled to move at a variable speed relative to each other, thereby forming zones or regions with different hardness characteristics. In Figure 2, a sheet base image 42 is superimposed on the diagram of the tractor belts 40a-40e. The sheet base image 42 is a preform strip 38 This represents the sheet being formed when the sheet is cut into individual sheet pad pieces and then formed in a mold into the shape of the sheet pad shown in the illustration.

[0018] The sheet pad image 42, indicated by dashed lines, includes a first hardness zone 44 and a second hardness zone 46. A first boundary 48 is formed between the first hardness zone 44 and the second hardness zone 46. A third hardness zone 50 and the second hardness zone 46 form a second boundary 52 between them. As shown in Figure 2, the first boundary 48 and the second boundary 52 are not perpendicular to the longitudinal or extrusion direction in which the belt moves, but instead converge from the front portion of the sheet base image 42 to the rear portion of the sheet base image 42.

[0019] It should be understood that boundaries 48 and 52 may be curved or positioned in a wide range of angular orientations with respect to the longitudinal direction in order to provide a desired variation in the hardness profile in a given zone or region of the molded seat cushion. The first boundary 48 and the second boundary 52 are preform strips 38 It can extend completely across or preform strips 38 The boundary can extend partially across the boundary. Alternatively, the boundary can be characterized as a transitional region between different hardness zones.

[0020] Various tractor belts 40a-40e are preformed strips. 38A first speed arrow 54, illustrating the different speeds acting on the tractor belt, is shown at the feed end of the tractor belt section 26. The size of the first speed arrow 54 corresponds to the speed at which each tractor belt is moving.

[0021] The second velocity arrow 56 is shown above the first velocity arrow 54 in Figure 2, and at a later point in time, the preform strip 38 This indicates that the speed of the tractor belts 40a-40e changes to locally alter the apparent / bulk density. Similarly, the third speed arrow 58 shown above the second speed arrow 56 in Figure 2 represents the preform strip 38 This shows that additional speed changes can be made to change the apparent / bulk density again. Each speed arrow 54、56,58 The length of the tractor belts 40a to 40e changes as the polymer filament 20 is stretched through the tractor section 26.

[0022] The apparent bulk density of the pad is controlled by the tractor belts 40a-40e. The apparent bulk density is not the same as the filament density, which is the density of a single strand. The strand spacing is controlled by the speed at which the tractor belts 40a-40e draw the strands into the cooling tank 24 or water tank. The apparent bulk density in each zone of the sheet base increases as the speed of the tractor conveyor belts 40a-40e decreases. Conversely, the apparent bulk density in each zone of the sheet base decreases as the speed of the tractor conveyor belts 40a-40e increases. There is an upper limit to the speed difference between adjacent tractor belts. If the speed difference is too large, some filaments may be excessively stretched, broken, thinned, or lose their bonding positions. The degree of variation in the apparent bulk density of the cushion is limited, but can approach a 60% variation from one zone to another.

[0023] Motors 60a to 60e are variable-speed motors controlled by controller 62. Controller 62 is programmed to individually change the motor speed and the movement of tractor belts 40a to 40e to match or correspond to the specified apparent / bulk density of the zones of the seat cushion being manufactured.

[0024] figure 5 See preform strip 38 is a preform strip 38 To show the change in apparent / bulk density across the preform strip, 38 This is shown in a cross-section across the width. Different apparent / bulk densities are indicated by relative looseness and compacting in different zones.

[0025] figure 3 and figure 4 Referring to the figure, 3 The seat backrest 64 is shown in the figure. 4 The sheet cushion 66 is shown, which includes a soft zone or region 68 and three different hard zones or regions 70, 72, and 74 with different hardness values. The hardness of the soft zone is, for example, 1.2 kPA, and the apparent / bulk density is 1.8 kg / m³. 3 The three different hard zones have hardnesses ranging from 1.2 kPA to 23.1 kPA and 1.8 kg / m³. 3 ~5.8 kg / m 3 It has an apparent / bulk density within the range of [value].

[0026] Referring to Figure 6, the vehicle seat assembly comprises a seat frame 76, a seat cover 78, a seat back cushion 64, and a seat base cushion 66. 80 The seat frame 76 and seat cover 78 are offered in a wide range of styles and designs. The seat back cushion 64 and seat base cushion 66 are initially pre-formed strips. 38 A polymer filament formed in a preform strip. 38It is divided into separate cushions or seat pads and is part of the vehicle seat assembly. 80 Preformed strips are molded before assembly. 38 It is divided into multiple seat back cushions 64 or seat base cushions 66, each of which is assembled to one of multiple seat frames 76 and covered by one of multiple seat covers 78.

[0027] The articles are randomly oriented and joined together to form a three-dimensional mesh structure. 38 Multiple extruded polymer filaments form a single structure. 20 of Preform strips, that is Main unit 38 Equipped with, Preform strip 38 This is an extruded polymer filament that is stretched longitudinally and has a first apparent / bulk density. 20 An extruded polymer filament having a first zone 42 including a first apparent / bulk density and a second apparent / bulk density lower than the first apparent / bulk density. 20 Including the second zone 46, which includes the second zone 46.

[0028] The articles described in the preceding paragraph may include one or more of the following additional features:

[0029] An article relating to one or more of the above clauses comprises a first zone 42 and a second zone 44, and the first zone 42 and the second zone 44 are Preform strip 38 Defining at least one boundary 48 or transitional area between the first zone 42 and the second zone 44, which extends at least partially across the zone.

[0030] Articles relating to one or more of the above items comprise a first zone 42 and a second zone 44, and the first zone 42 and the second zone 44 are Preform strip 38 Define at least one boundary 48 between the first zone and the second zone that extends completely across the area.

[0031] Articles made according to one or more of the above items are the main body 38The system includes at least one boundary 48 between the first zone 42 and the second zone 44, which extends at an angle less than perpendicular to the longitudinal direction in which the system moves.

[0032] An article relating to one or more of the above items comprises at least one curved boundary 48 between the first zone 42 and the second zone 44.

[0033] Articles made according to one or more of the above items are multiple connected intermediate preforms 38 including Preform strip 38 Equipped with intermediate preform 38 Each of these is separated and fitted to be molded into seat cushions 64, 66.

[0034] Seat assembly 80 is a seat frame 76 And, seat cover 78 The main body includes a seat back cushion 64 and a seat base cushion 66. 38 These are randomly oriented and joined together to form intermediate preforms. 38 Multiple extruded polymer filaments form a single structure. 20 Includes intermediate preform 38 This is an extruded polymer filament having a first apparent / bulk density. 20 An extruded polymer filament having a first zone 44 and a second apparent / bulk density lower than the first apparent / bulk density. 20 Extruded polymer filaments containing 20 The second zone 46 and the intermediate preform 38 These are molded to form a molded backrest cushion 64 and a seat base cushion 66.

[0035] The seat assembly described in the previous paragraph may include one or more of the following additional features:

[0036] A seat assembly according to one or more of the above items comprises a first zone 42 and a second zone 44, the first zone 42 and the second zone 44 being the main body 38Defines at least one boundary 48 or transition area between the first zone 42 and the second zone 44, which extends at least partially across the zone.

[0037] A seat assembly according to one or more of the above items comprises a first zone 42 and a second zone 44, the first zone 42 and the second zone 44 being the main body 38 Define at least one boundary 48 between the first zone 42 and the second zone 44 that extends completely across the zone.

[0038] A seat assembly according to one or more of the above items includes at least one curved boundary 48 between the first zone 42 and the second zone 44.

[0039] The method is polymer resin 16 The process involves melting the material to form a molten polymer, and the die head 18 Extruded polymer filaments by extruding molten polymer through this process. 20 Forming and extruded polymer filaments 20 a filament having a predetermined cross-section 20 This method includes forming and joining strips of filament. This method uses a plurality of tractor belts 40a to 40e arranged transversely to the longitudinal direction, 20 The strip of the cooling tank 24 Further including pulling inward in a longitudinal direction, tractor belts 40a to 40e each contain stripped filaments. 38 Move one of the multiple parts of the filament in the longitudinal direction. Multiple tractor belts 40a-40e are filament 20 Control one of the multiple sections of the strip to move at a different speed relative to the other tractor belts 40a-40e of the polymer filament 20 Filament across the width of the strip 20 To locally control the apparent / bulk density of multiple parts of the strip.

[0040] The method described in the previous paragraph may include one or more of the following additional features:

[0041] above Methods according to one or more of the above include forming multiple seat cushion preforms 64, 66 by aligning filaments transversely to the longitudinal direction. 20 This further includes cutting the strip.

[0042] above by one or more of the following items method This further includes molding multiple seat pad preforms 64, 66 into the contour shape of a seat cushion.

[0043] above by one or more of the following items method So, polymer resin 16 It is a thermoplastic polymer such as LLDPE or HDPE.

[0044] above by one or more of the following items method This includes filament strips, including sheet pads 64 and 66. 38 This further includes assembling it to the seat frame.

[0045] above by one or more of the following items method This further includes covering the seat pads 64 and 66 with seat covers.

[0046] A seat assembly comprising one or more of the above items is manufactured according to this method.

[0047] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the Disclosure. In this regard, the terms used herein are descriptive rather than restrictive, and it should be understood that various modifications can be made without departing from the spirit and scope of the Disclosure. Furthermore, features of various embodiments can be combined to form further embodiments of the Disclosure.

Claims

1. The process involves melting polymer resins to form molten polymers, The process involves extruding the molten polymer through a die head to form an extruded polymer filament, The extruded polymer filament is formed and joined to a strip of filament having a predetermined cross-section, The filament strip is pulled into a cooling tank in the longitudinal direction using a plurality of tractor belts arranged transversely to the longitudinal direction, wherein each tractor belt moves one of the plurality of portions of the filament strip in the longitudinal direction, and the filament strip is pulled in. Controlling the plurality of tractor belts to move one of the plurality of portions of the filament strip at a different speed relative to the other tractor belts of the plurality of tractor belts, thereby locally controlling the density of the plurality of portions of the filament strip across the width of the polymer filament strip, Methods that include...

2. The method according to claim 1, further comprising cutting the filament strip in a direction transverse to the longitudinal direction to form a plurality of sheet pad preforms.

3. The method according to claim 2, further comprising molding the plurality of sheet pad preforms into the contour shape of the plurality of sheet pads.

4. The method according to claim 3, further comprising assembling each of the plurality of seat pads to one of the plurality of seat frames.

5. The method according to claim 3, further comprising covering each of the plurality of seat pads with one of the plurality of seat covers.

6. The method according to claim 1, wherein the polymer resin is HDPE.

7. The method according to claim 1, wherein the polymer resin is a thermoplastic polymer.

8. The method according to claim 1, wherein the polymer resin is LLDPE.

Images