Method for manufacturing mesh structures and cross-referencing with related applications

Abstract

The present invention relates to a filament mesh structure, a method for manufacturing and forming the filament mesh structure, and a sheet assembly having the filament mesh structure, which may be cut by a fluid jet and heated with a fluid to facilitate reshaping, and which may include foldable connecting segments to facilitate folding of the filament mesh structure.

Description

Technical Field

[0001] [Cross - References to Related Applications] This application claims the benefit of Danish Patent Application No. PA202370186, filed on April 21, 2023, which in turn claims priority to U.S. Provisional Application No. 63 / 354,288, filed on June 22, 2022; U.S. Provisional Application No. 63 / 355,785, filed on June 27, 2022; and U.S. Provisional Application No. 63 / 356,719, filed on June 29, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] Various embodiments relate to a filament mesh structure such as a cushion, a sheet assembly having a filament mesh structure cushion, and one or more methods of manufacturing and forming a filament mesh structure.

Brief Description of the Drawings

[0003] [Figure 1] A perspective view of an example of a sheet assembly. [Figure 2] A perspective view of an example of a cushion including a filament mesh structure that can include a sheet assembly. [Figure 3] A schematic view of an example of a manufacturing system for manufacturing a filament mesh structure. [Figure 4] A perspective view of an example of a cutting system for cutting a filament mesh structure. [Figure 5A] A schematic side view of various cuts that can be performed with the cutting system. [Figure 5B] A schematic side view of various cuts that can be performed with the cutting system. [Figure 5C] A schematic side view of various cuts that can be performed with the cutting system. [Figure 5D] A schematic side view of various cuts that can be performed with the cutting system. [Figure 5E]This is a schematic side view of the various cuts that can be performed with the cutting system. [Figure 5F] This is a schematic side view of the various cuts that can be performed with the cutting system. [Figure 5G] This is a schematic side view of the various cuts that can be performed with the cutting system. [Figure 6A] This is a schematic top view of various cuts that can be performed with the cutting system. [Figure 6B] This is a schematic top view of various cuts that can be performed with the cutting system. [Figure 7] This shows an example of a molding system for forming a filament mesh structure using a molding tool indicated in its storage position. [Figure 8] Figure 7 shows a molding system in which steam is blown onto a filament mesh structure. [Figure 9] Figure 7 shows a molding system in which a molding tool is engaged with a filament mesh structure. [Figure 10] Figure 7 shows the molding system with the molding tool in its storage position after the filament mesh structure has been reshaped. [Figure 11] This is a perspective view of another example of a molding system for forming a filament mesh structure, in which a molding tool is engaged with the filament mesh structure to reshape it. [Figure 12] This is a cross-sectional view along section line 12-12 with the molding tool before steam is sprayed to engage the filament mesh structure. [Figure 13] This is a perspective view of another example of a molding system for forming a filament mesh structure, wherein steam is sprayed through a nozzle to reshape the filament mesh structure. [Figure 14] This is a magnified view of a portion of a filament mesh structure, showing an example of a filament before heating and reshaping. [Figure 15] This is an enlarged view of a portion of the filament mesh structure in Figure 14, which shows an example of a filament after heating and reshaping. [Figure 16]Figures 7 to 13 are flowcharts illustrating the method for forming the filament mesh structure related to the configuration of the molding system. [Figure 17] These are top and side views of some examples of filament mesh structures. [Figure 18] These are top and side views of some examples of filament mesh structures. [Figure 19] Figures 17 and 18 show the top and side views of the filament mesh structure after molding. [Figure 20] Figures 17 and 18 show the top and side views of the filament mesh structure after molding. [Figure 21] Figures 19 and 20 show the top and side views of the filament mesh structure after folding. [Figure 22] Figures 19 and 20 show the top and side views of the filament mesh structure after folding. [Figure 23] Figure 22 is a side view of the filament mesh structure with the folded portion fixed in the folded position.

[0004] [Detailed explanation] Herein, embodiments are given detailed reference, and examples of such embodiments are shown in the accompanying drawings. In the following detailed description, numerous specific details are given in order to fully understand the various embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described can be carried out without these specific details. In other examples, well-known methods, procedures, components, circuits, and networks are not described in detail so as not to unnecessarily obscure the aspects of the embodiments.

[0005] It should be understood that the disclosed embodiments are merely illustrative and that various alternative forms are possible. The figures are not necessarily to scale, and some features may be exaggerated or minimized to illustrate the details of specific components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative grounds to instruct those skilled in the art on various uses of the embodiments disclosed herein.

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

[0007] While terms such as "first," "second," etc., are used in some examples to describe various elements in this specification, 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 can be called a second contact, and similarly, a second contact can be called a first contact. Both the first and second contacts are contacts, but they are not the same contact.

[0008] In the description of the various embodiments described in this specification, the terms used are for the purpose of describing only the specific embodiments and are not intended to be limiting. As used in the description of the various embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. Also, the term "and / or" as used in this specification refers to any and all possible combinations of one or more of the associated listed items and is understood to be inclusive. Further, words such as "have", "had", "include", and / or "included" when used in this specification, while specifying the presence of the described features, integers, steps, operations, elements, and / or components, do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0009] As used in this specification, the term "if" will be interpreted, depending on the context, optionally, to mean "when" or "upon" or "in response to detecting". Similarly, the phrases "if it is determined" or "if [the described condition or event] is detected" will be interpreted, depending on the context, optionally, to mean "upon determining" or "in response to determining" or "upon determining" or "in response to determining" or, "upon detecting [the described condition or event]" or "in response to detecting [the described condition or event]".

[0010] Further, unless otherwise explicitly indicated, all numerical values in this specification and the claims are to be understood as being modified by the word "about" when describing a broader scope of the present invention. The terms "substantially", "approximately" or "about" can be used in this specification and can modify the values or relative characteristics described in the disclosure or claims. In such cases, "substantially", "approximately" or "about" can mean that the value or relative characteristic being modified is within the range of ±0%, 0.1%, 0.5%, 1%, 2%, 4%, 5%, or 10% of the value or relative characteristic. Implementations within the described numerical limits are generally preferred. Also, unless explicitly stated to the contrary, descriptions of groups or classes of materials suitable or preferred for a given purpose in connection with the present invention mean that mixtures of any two or more members of the group or class are equally suitable or preferred.

[0011] Referring to FIG. 1, an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for a land vehicle such as an automobile, truck, bus, etc., or a non-land vehicle such as an aircraft or a ship. For example, the seat assembly 10 for a land vehicle can have a shape and size as a front row driver's seat or passenger seat, a second row, a third row, or other rear row seats, and can include a bench-style seat, a bucket seat, or other seat styles as shown. Further, the seat assembly 10 can be a non-stowable seat or a stowable seat that can be folded and stored in a cavity within the vehicle floor. Additionally, the seat assembly 10 can be configured for non-vehicle applications such as furniture.

[0012] In the configuration shown in FIG. 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is conceivable that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or a stool.

[0013] The seat bottom 20 is configured to receive a seated occupant and support the occupant's pelvis and thighs. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0014] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and may be made of any suitable material such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In one or more configurations, the seat bottom frame 30 includes a panel, seat pan, suspension mat, or suspension wire on which the cushion 32 is placed.

[0015] The cushion 32 is positioned on the seat bottom frame 30. The cushion 32 is made of a flexible material that supports the seat occupant and distributes the load from the seat occupant to the seat bottom frame 30. The cushion 32 and related manufacturing methods are described in more detail below.

[0016] The trim cover 34 covers at least a portion of the cushion 32. Furthermore, the trim cover 34 provides one or more visible outer surfaces of the seat back 22. A seat occupant can be positioned over the trim cover 34 when seated in the seat assembly 10. The trim cover 34 is made of any suitable material or combination thereof, such as cloth, leather, leatherette, vinyl, or a combination thereof. The trim cover 34 may include multiple trim panels assembled by any suitable method, such as fusion or stitching. The trim cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may include trim mounting features attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 and to help conform the trim cover 34 to the contours of the seat bottom frame 30, the cushion 32, or both.

[0017] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is positioned adjacent to the seat bottom 20. For example, the seat back 22 may be positioned above the seat bottom 20 and near the rear of the seat bottom 20. The seat back 22 extends generally upward away from the seat bottom 20. In some configurations, the seat back 22 may be attached to the seat bottom 20 and rotatable relative to the seat bottom 20. In other configurations, the seat back 22 is not attached to the seat bottom 20. For example, the seat back of a vehicle may be attached to the vehicle body structure, such as in some second-row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a trim cover 44, and optionally a headrest 46.

[0018] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and may be made of any suitable material such as a metal alloy, polymer material, fiber-reinforced polymer material, or a combination thereof. In one or more configurations, the seat back frame 40 includes a panel, pan, suspension mat, or suspension wire on which the cushion 42 is placed. The seat back frame 40 may also be formed integrally with the seat bottom frame 30.

[0019] The cushion 42 is positioned on the seat back frame 40. The cushion 42 is made of a flexible material that supports the seat occupant and distributes the load from the seat occupant to the seat back frame 40. The cushion 42 may be formed integrally with the cushion 32 of the seat bottom 20, or it may be separated from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods are described in more detail below.

[0020] The trim cover 44 covers at least a portion of the cushion 42. Furthermore, the trim cover 44 provides one or more visible outer surfaces of the seat back 22. When a seat occupant is seated in the seat assembly 10, they may be positioned on the trim cover 44. The trim cover 44 is made of any suitable material or combination of materials, such as cloth, leather, leatherette, vinyl, or a combination thereof. The trim cover 44 may include multiple trim panels assembled in any suitable way, such as fusion or stitching. The trim cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 may include trim mounting features attached to the seat back frame 40, the cushion 42, or both to prevent the trim cover 44 from being removed and to help the trim cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both.

[0021] The headrest 46, if provided, is configured to support the head of the seat occupant. The headrest 46 is located on the upper part of the seat back 22, or at the end of the seat back 22, on the side opposite to the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or it may be formed integrally with the seat back 22.

[0022] An example of cushion 50 is shown in Figure 2. For convenience of reference, the cushions are collectively referred to by reference number 50. Please understand that the structure and description of cushion 50 are applicable to cushion 32 of the seat bottom 20, cushion 42 of the seat back 22, or both.

[0023] The cushion 50 is a non-foaming component or contains at least one non-foaming component. The non-foaming component is mainly called a filament mesh structure, but may also be called a stranded mesh, mesh cushion, mesh structure, or mesh member. In Figure 2, the cushion 50 is shown as a non-foaming component that does not contain a foaming component or foaming material such as urethane foam or polyurethane foam. However, the cushion 50 may also contain a foaming component or foaming material in addition to the non-foaming component to provide additional cushioning or localized cushioning for the seat occupant. For example, the foaming material may be provided between the cushion 50 and a trim cover (e.g., trim covers 34, 44) placed on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foaming material provided with the cushion 50 or removing material from the cushion 50 can reduce weight and improve support and comfort for the seat occupant.

[0024] The cushion 50 is described below primarily in relation to a non-foaming component that does not contain foaming material. In this context, the cushion 50 is made of filaments 52 of a polymer material that are randomly bent, curled, or looped and bonded together as described below in detail.

[0025] The filament 52, also called a strand or thread, can be made from any suitable material or a combination of materials. In some configurations, the filament 52 is made from a thermoplastic material or a thermoplastic resin, such as a polyamide, polyester, polyimide, polyolefin, polypropylene, polystyrene, or a combination thereof. For example, a polyethylene filament may be made from linear low-density polyethylene (LLPDE). Unlike foamed materials, filament materials are recyclable or can be recycled more easily than foamed materials. It is also conceivable that the filament 52 includes reinforcing fibers, and the reinforcing fibers do not have to be made from a thermoplastic material.

[0026] The filament 52 may be a monofilament made of a single material, or it may be a filament made of multiple materials. For example, a filament 52 made of multiple materials may include a core made of a first thermoplastic material and a sheath surrounding the core, made of a second thermoplastic material different from the first thermoplastic material. The cushion 50 may also include a combination of a monofilament and a filament made of multiple materials that is not a monofilament.

[0027] The filaments 52 may be randomly bent, looped, curled, or intertwined, and may be joined together where one filament 52 comes into contact with another filament 52, thereby creating a lightweight, air-permeable cushion (e.g., cushions 32 and / or 42) or mesh structure with openings or voids between the filaments 52. An enlarged view of an example of filaments 52 in a mesh structure is shown in Figure 14. An example of a method for manufacturing a mesh cushion or mesh structure is disclosed in U.S. Patent Application No. 17 / 555,875, which is incorporated herein by reference in its entirety. An example of a manufacturing system 60 for manufacturing a cushion or mesh structure of filaments is also shown in Figure 3. In this example, the manufacturing system 60 includes a hopper 70, an extruder 72, a funnel 74, a tank 76, and a material processing subsystem 78.

[0028] Referring to Figure 3, the container or hopper 70 holds the material to be extruded, such as solid beads, flakes, granules, pellets, or powders manufactured from the material. The hopper 70 supplies the material to the extruder 72.

[0029] The extruder 72 melts the material and extrudes it onto the filament 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw moves the material through the barrel and helps heat the material by the friction generated as the screw rotates. The material exits the barrel in a molten state under pressure and is transported to the die 80 of the extruder 72.

[0030] The die 80, also called a die plate or extrusion die, has a plurality of through holes or filament-forming openings through which the molten material passes. A single filament 52 is extruded from each through hole. The filament 52 falls downward from the die 80 toward the funnel 74 under gravity.

[0031] The funnel 74 integrates or groups the filaments 52 into a more compact arrangement, where the filaments 52 bend, curl, or loop, and each filament 52 contacts and connects with at least one other filament 52. The funnel 74 has a funnel inlet and a funnel outlet smaller than the funnel inlet. Individual, separated filaments 52 enter the funnel inlet. As the filaments 52 accumulate, they bend, curl, or loop and move to make contact. The filaments 52 slide down the funnel 74 toward the funnel outlet. Connections are formed between the filaments 52 at the contact points, but at other locations where one filament 52 does not contact or connect with the other filament 52, there are openings or gaps between the filaments 52. The entangled and connected filaments 52 pass through the funnel outlet of the funnel 74 and enter the tank 76. For convenience of reference, the connected filaments 52 are referred to as a filament mesh structure 90.

[0032] Tank 76 holds a liquid, such as water or a mixture of water and other fluids. The liquid in tank 76 supports the tangled and bonded filaments 52, limiting further compression or compaction of the filaments 52 and helping to maintain the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance that allows the filaments 52 adjacent to the liquid surface to bend, curl, or loop further in order to further construct the filament mesh structure 90. The liquid also cools the filaments 52 when they are in the liquid. For example, the liquid cools the filaments 52 from the outside, causing them to solidify and preventing them from bonding in other places. At this point, the filaments 52 are relatively hard, no longer in a plastic state, and therefore generally maintain their shape and cannot be molded or deformed without heating.

[0033] The material processing subsystem 78 transports the filament mesh structure 90 through the tank 76. The material processing subsystem 78 includes various rollers and conveyors to help move the filament mesh structure 90 in and out of the liquid. In some configurations, a tractor conveyor 92 is provided inside the tank 76 to help pull the filament mesh structure 90 away from the funnel 74 and counteract the buoyancy of the filaments 52.

[0034] Other rollers, such as roller 94, keep the filament mesh structure 90 submerged in the liquid and guide it through the tank 76. For example, roller 94 can guide the filament mesh structure 90 toward a conveyor belt 96 and a shaker table 98 located outside the tank 76. The shaker table 98 shakes the filament mesh structure 90 on the conveyor belt 96 to remove the liquid. Alternatively or additionally, the filament mesh structure 90 can be squeezed to remove the liquid, pressurized air can be blown toward the filament mesh structure 90 to remove the liquid, or both.

[0035] The manufacturing system 60 described above is a continuous flow process in which the filament mesh structure 90 is formed as a continuous structure when filament extrusion is not interrupted. Further processing of the filament mesh structure 90 is performed after it leaves the tank 76, cutting the filament mesh structure 90 into individual parts for individual cushions, providing cushions 50 of the desired size and shape. For example, the cross-sectional shape of the filament mesh structure 90 can correspond to the shape of the funnel outlet. A manufacturing system 60 having a funnel outlet with a rectangular opening produces a filament mesh structure 90 with a substantially rectangular shape or a rectangular cross-section. If cushions 50 with different shapes or different cross-sections are desired, additional contouring or molding steps are performed. For example, the filament mesh structure 90 may be cut to remove material and shape or contour the outer surface to provide through holes, blind holes, notches, grooves, trenches, or slits, or a combination thereof. Cutting, contouring, and molding of the mesh material can be achieved using a cutting system 100.

[0036] Referring to Figure 4, an example of the cutting system 100 is shown. The cutting system 100 is a fluid-based cutting system that provides a pressurized fluid for cutting one or more filaments 52 of the filament mesh structure 90. Thus, the fluid is the cutting medium. The fluid is mainly described below as a liquid, e.g., liquid water, or a fluid containing liquid water. However, the fluid may also be a gas, and an abrasive material may be added to the fluid as the cutting medium. In some configurations, the cutting system 100 includes a platform 110, a fluid supply subsystem 112, a cutting head 114, an automation (automatic device) 116, and a controller 118. The cutting system 100 may have additional fluid system components such as filters, accumulators, and vents, which are not shown for simplification.

[0037] The platform 110 supports the filament mesh structure 90. In some configurations, the platform 110 is configured as a table or workstation that supports the filament mesh structure 90 in a fixed position. In other configurations, the platform 110 is a conveyor that supports the filament mesh structure 90 and is configured to move the filament mesh structure 90. The platform 110 may include a water collector 120 that collects or receives fluids such as liquid discharged or sprayed by the cutting head 114. For example, the water collector 120 may be provided with the platform 110 or may be configured as a pan or tray placed beneath the platform 110. The water collector 120 may be fluid-connected to a fluid supply subsystem 112, for example, if the fluid is a liquid.

[0038] The fluid supply subsystem 112 supplies fluid to the cutting head 114. The fluid supply subsystem 112 includes a fluid source 130, a pump 132, and one or more fluid regulators 134.

[0039] The fluid source 130 contains or supplies fluid. The fluid source 130 may be pressurized or unpressurized. Examples of pressurized fluid sources include pressurized tanks and pressurized supply lines. Examples of unpressurized fluid sources are open tanks or reservoirs. In some configurations, the fluid source 130 receives fluid from the water collector 120 and allows the fluid to be recycled or reused.

[0040] Pump 132 is fluid-connected to or can be fluid-connected to the fluid source 130 and the cutting head 114. Pump 132 increases the fluid pressure to facilitate the delivery of fluid to the cutting head 114.

[0041] One or more fluid regulators or fluid control devices 134, such as valves, are provided to control the flow of fluid, such as the flow of fluid from the fluid source 130 to the cutting head 114.

[0042] The pump 132 and the fluid regulating device 134 may be controlled, as described below, to control the fluid flow to the cutting head 114, for example, by allowing or starting the fluid flow, stopping the fluid flow, controlling the fluid pressure, and controlling the fluid flow rate.

[0043] The cutting head 114 includes a nozzle 140 that provides a jet or flow of fluid. The jet or flow of fluid is configured to cut the filament 52 when directed towards the filament 52 with sufficient pressure. The jet or flow of fluid can extend axially from the outlet or outlet orifice of the nozzle 140. The nozzle 140 is in fluid communication or fluid connection to the fluid supply subsystem 112 via a conduit such as a hose or pipe. The cutting head 114 is mounted on automation 116.

[0044] The automation 116 is configured to position the cutting head 114. In some configurations, the automation 116 is a robotic arm, a robotic manipulator, or a linear actuator. The automation 116 may be a single-axis automation, a two-axis automation, a three-axis automation, or may have more than three axes to provide greater degrees of freedom for the automation's movement. For example, the automation 116 may have up to six degrees of freedom, including degrees of freedom of movement in translation in the X, Y, and Z (horizontal, vertical, and depth) directions, and one or more of rotations by pitch, yaw, and roll.

[0045] The automation 116 can facilitate cutting the filament mesh structure 90 by holding the cutting head 114 in a stationary position relative to the filament mesh structure 90 or by moving the cutting head 114. In one example, the automation 116 may include one or more actuators 150 configured to move the cutting head 114. For example, the actuators 150 may be configured to move the cutting head 114 along a linear path, such as when the automation 116 moves along an axis or in a plane such as the XZ plane shown in Figure 4. In other examples, the automation 116 may include one or more actuators 150 configured to move or cooperate for movement of the cutting head 114 in a complex path across the filament mesh structure 90, such as in directions in a path including non-linear paths, linear paths, or combinations thereof in the XY plane, and / or move the cutting head 114 vertically or in the YZ plane, such as moving the cutting head 114 toward or away from the filament mesh structure 90, for automation with multiple degrees of freedom.

[0046] Furthermore, the automation 116 may include additional actuators 150 that control the angle of the cutting head 114 relative to the filament mesh structure 90 and allow rotation or tilting of the cutting head 114 relative to the X, Y, and Z axes or planes. The rotation or tilting of the cutting head 114 allows for angled cuts relative to the XY, YZ, and XZ planes, such as chamfers, angled slits, or V-shaped trenches.

[0047] In some configurations, the automation 116 has at least one fixed support member extending across the filament mesh structure 90, which moves one or more actuators 150 and the cutting head 114 relative to each other, for example, by sliding the cutting head 114 across or along the support member.

[0048] The controller 118 monitors and controls the operation of the cutting system 100. The controller 118 includes one or more controllers or control modules, which may be distributed or centralized. Some or all of the controllers may be connected by a Controller Area Network (CAN) or other system. The controller 118 communicates with various components of the cutting system, such as the platform 110 (e.g., the pump 132 and the fluid regulator 134), the fluid supply subsystem 112, and the automation 116.

[0049] The controller 118 receives inputs or input signals from sensors provided with the cutting system 100, such as proximity sensors, speed sensors, pressure sensors, and flow sensors, for use in controlling the cutting system 100. Furthermore, the controller 118 can receive inputs from other systems or users in the manufacturing process. For example, the controller 118 receives an input indicating the density of the filament mesh structure 90.

[0050] The controller 118 is configured to control the speed of the platform 110, which is configured as a conveyor, including stopping, starting, and changing the direction of movement. For example, the speed of the conveyor can be stopped or reduced when cutting is taking place.

[0051] The controller 118 is configured to control the movement of the automation 116 by controlling its actuator 150, and thus controls the position, orientation, and movement speed or transfer speed of the cutting head 114 and nozzle 140 relative to the filament mesh structure 90.

[0052] The controller 118 is configured to control the fluid flow from the nozzle 140 by controlling the pump 132 and the fluid adjustment device 134, thereby allowing, increasing, decreasing, and stopping the fluid flow to the nozzle 140. The controller 118 is configured to increase, decrease, or maintain the fluid pressure supplied to the nozzle 140, the fluid flow rate in the nozzle 140, or both.

[0053] It is recognized that the controller 118 or other electrical devices disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., flash, random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variants thereof) and software that cooperate or work together to perform the operations disclosed herein. Furthermore, any one or more electrical devices disclosed herein may be configured to run a computer program embodied in a non-temporary computer-readable medium programmed to perform any number of the functions disclosed herein.

[0054] The controller 118 is configured to control the speed of the cutting head 114, as well as the pressure and flow rate of the fluid flowing out of the nozzle 140, depending on the thickness of the filament mesh structure 90 and the selected depth of the cut into the filament mesh structure 90. Furthermore, the controller 118 can control the cutting head 114 and the cutting system 100 to provide either a single-pass cut or a multi-pass cut where the selected cut requires multiple passes of the cutting head 114 along the cutting path.

[0055] The cutting system 100 can provide planar cutting, or cutting along a single plane aligned with or angled relative to the X, Y, and / or Z planes. Planar cutting can result in planar side or surface cuts of the filament mesh structure 90. Furthermore, the cutting system 100 can provide cutting along a single axis.

[0056] The cutting system 100 can provide cutting across the filament mesh structure 90 to separate the filament mesh structure into separate parts, either by a single pass of the cutting head 114 through the filament mesh structure 90 or by multiple passes of the cutting head 114.

[0057] Furthermore, the cutting system 100 is controllable in a manner that provides a variable cutting depth. Since the filaments 52 are bent, looped, or otherwise shaped in various directions with gaps between them, the presence and position of the filaments 52 within the filament mesh structure 90 changes. Therefore, the cutting system 100 is controllable to adjust the fluid jet depending on the presence, quantity, size, or absence of the filaments 52 at the location where the cut is provided within the filament mesh structure 90. For example, the cutting system 100 is controllable when cutting multiple filaments, when cutting filaments of a larger diameter, or when reaching and cutting filaments located at a greater depth or distance from the nozzle 140. In the case of cuts such as partial cuts that do not completely penetrate the filament mesh structure 90, the cutting system 100 can operate with additional passes of the cutting head 114 at a lower speed, lower fluid pressure, and / or lower fluid flow rate to improve the accuracy and / or precision of the cut into the filament mesh structure 90.

[0058] The cutting system 100 is configured to provide several types of cuts to the filament mesh structure 90. These include through cuts and partial cuts or "blind cuts" in the filament mesh structure 90. Through cuts can provide through holes or slits that separate the filament mesh structure 90 into separate pieces or not into separate pieces. Partial cuts do not completely penetrate the filament mesh structure 90 and can be used to provide blind holes, trenches, slits, or slots. According to various examples, the cutting system 100 can be controlled to provide orthogonal cuts, bevels, fillets, radii, etc.

[0059] Figures 5A to 5G show some examples of the various cuts that can be provided by the cutting system 100, along with diagrams that may be either side views or cross-sectional views of a filament mesh structure (e.g., filament mesh structure 90). These examples are not exhaustive. In these diagrams, the filament mesh structure 90 is represented as a rectangular block before cutting. Dashed lines are used to represent the area of ​​the rectangular block to be cut.

[0060] Figure 5A shows a vertical cut 160 which can produce orthogonal sides or orthogonal surfaces. Figure 5B shows an undercut fillet 162. Figure 5C shows a fillet 164. Figure 5D shows a chamfer 166. Figure 5E shows two partial cuts of different cut depths for forming two trenches 168, which may be a side view or a cross view. Figure 5F shows through slots or through holes 170 and blind holes 172 as cross views. Figure 5G shows a V-shaped channel 174 and an angled partial cut 176, also called a channel, recess, or slit, which may be a side view or a cross view. The V-shaped channel 174 may have a greater depth and may extend through the filament mesh structure 90. The V-shaped channel 174 or angled partial cut 176 is provided by performing two cuts, such as a blind cut, along different cutting paths that are angled to each other and intersect.

[0061] Figures 6A and 6B show top views of filament mesh structures (e.g., filament mesh structure 90) with various cuts that can be provided by the cutting system 100. These examples are not exhaustive. Figure 6A shows a double chamfer 178 and a trench 168 cut to a partial depth and extending laterally across the filament mesh structure 90. Figure 6B shows an example of a curved cut or curved contour 180. The curved side may have a convex section, a concave section, or a combination thereof. Figure 6B also shows an example of a trench 182 which has a through hole 170 and two angled sections connected by an arcuate portion, extends only partially across the filament mesh structure 90, and is either a through cut or a partial cut.

[0062] It should be understood that the cutting system 100 can provide cuts along various sides of the filament mesh structure 90. Furthermore, the cutting system 100 can provide through cuts and partial cuts in three dimensions along straight and non-straight paths. For example, the cutting system 100 can provide curved or contoured surfaces when viewed along multiple axes, such as any combination of the X, Y, and Z axes.

[0063] The controller 118 is configured to simultaneously control the movement of the automation 116 and the flow and pressure of the fluid supplied to the nozzle 140 by the fluid supply subsystem 112 in order to provide a desired type of cut at a desired location. In some examples, deeper cuts may be provided by controlling the automation 116 to move the cutting head 114 at a slower speed, controlling the automation 116 to move the nozzle 140 closer to the filament mesh structure 90, controlling the automation 116 to move the nozzle 140 along multiple or repeated cutting passes, increasing the fluid flow rate to the nozzle 140, increasing the fluid velocity to the nozzle 140, or performing a combination of these. Similarly, shallower cuts may be provided by controlling the automation 116 to move the cutting head 114 at a faster speed, controlling the automation 116 to move the nozzle 140 further away from the filament mesh structure 90, controlling the automation 116 to move the nozzle 140 along fewer cutting passes or to avoid repeating cutting passes, decreasing the fluid flow rate to the nozzle 140, or performing a combination of these.

[0064] Control parameters associated with a particular type of cut can be based on experimentation or modeling. For example, a filament mesh structure 90 can be manufactured in a manufacturing system 60. The number of filaments extruded through the die 80, the size of the filaments (e.g., cross-sectional area), and the filament extrusion speed are recorded as relevant filament parameters. The density of the resulting filament mesh structure 90 is then measured and recorded, for example, by hydrostatic metering. Sample cutting can then be performed in a cutting system 100 with various cutting head speeds, fluid pressures, and fluid flow rates to determine whether the combination of speed, pressure, and flow rate is sufficient to provide the desired cut in the filament mesh structure 90. Allowable ranges or combinations of speed, pressure, and flow rate can be recorded or stored in memory and associated with the density of the filament mesh structure 90, since the density has been measured in advance. The allowable ranges or combinations are then input to or used in a controller 118 to control the cutting system 100 based on the density of the filament mesh structure 90.

[0065] As a non-limiting example, nozzle 140 has a diameter of 8 / 1000 inch and operates at a distance of 5 mm to 10 mm from the filament mesh structure 90. The fluid jet is supplied at a pressure in the range of 58,000 to 70,000 psi (399,895 to 482,633 kPa), and the nozzle has a velocity in the range of 1 to 75 mm / s against the filament mesh structure 90. The fluid jet provides a penetrating cut into the filament mesh structure 90 with a filament diameter of 0.5 mm and a density in the range of 2.7 to 3.4 pounds / cubic foot (43.2 to 54.5 kg / m3). In other examples, each of the nozzle diameter, distance, nozzle velocity, pressure, and / or density or filament diameter of the filament mesh structure 90 may be greater or less than the stated range or value.

[0066] Throughput can be increased by using multiple cutting systems 100, such as cutting systems arranged in parallel or in series. In addition, the filament mesh structure 90 can also be cut using other cutting techniques, such as mechanical cutters like cutting wheels, in combination with cutting with the cutting systems 100.

[0067] The method associated with the cutting system 100 is used to form cushions (e.g., cushions 32 and / or 42) and optionally to assemble sheets (e.g., sheet assembly 10). In various examples, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0068] This method involves cutting a filament mesh structure (e.g., filament mesh structure 90) with a fluid jet (e.g., fluid jet 150).

[0069] In some embodiments, cutting a filament mesh structure (e.g., filament mesh structure 90) with a fluid jet (e.g., fluid jet 150) forms a cushion (e.g., cushion 32 and / or 42) at least partially.

[0070] In some embodiments, this method includes attaching cushions (e.g., cushions 32 and / or 42) to the frame (e.g., frame 30 and / or 40) of a seat assembly (e.g., seat assembly 10).

[0071] In some embodiments, this method includes positioning a trim cover (e.g., trim cover 34 and / or 44) on a cushion (e.g., cushion 32 and / or 42) and attaching the trim cover (e.g., trim cover 34 and / or 44) to the cushion (e.g., cushion 32 and / or 42), a frame (e.g., frame 30 and / or 40), or the cushion (e.g., cushion 32 and / or 42) and a frame (e.g., frame 30 and / or 40).

[0072] In some embodiments, the method involves forming a filament mesh structure (e.g., filament mesh structure 90) with filaments of a thermoplastic material (e.g., filament 52), where the filaments (e.g., filament 52) ​​are randomly looped and joined together.

[0073] In some embodiments, forming a filament mesh structure (e.g., filament mesh structure 90) involves extruding a thermoplastic material through a die (e.g., die 80) to form filaments (e.g., filament 52), and then passing the filaments (e.g., filament 52) ​​through a funnel (e.g., funnel 74).

[0074] In some embodiments, this method includes cutting a filament mesh structure (e.g., filament mesh structure 90) after the filament (e.g., filament 52) ​​has passed through a funnel (e.g., funnel 74).

[0075] In some embodiments, this method includes controlling the movement speed of a cutting head (e.g., cutting head 114) to control the depth of cuts (e.g., vertical cuts 160, undercut fillets 162, fillets 164, chamfers 166, trenches 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved contours 180, trenches 182) into a filament mesh structure (e.g., filament mesh structure 90).

[0076] In some embodiments, this method involves reducing the travel speed of the cutting head (e.g., cutting head 114) to increase the depth of the cuts (e.g., vertical cuts 160, undercut fillets 162, fillets 164, chamfers 166, trenches 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved contours 180, trenches 182) into the filament mesh structure (e.g., filament mesh structure 90).

[0077] In some embodiments, this method involves moving the cutting head (e.g., cutting head 114) closer to the filament mesh structure (e.g., filament mesh structure 90) to increase the depth of the cuts (e.g., vertical cuts 160, undercut fillets 162, fillets 164, chamfers 166, trenches 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved contours 180, trenches 182) into the filament mesh structure (e.g., filament mesh structure 90).

[0078] In some embodiments, this method includes increasing the fluid pressure supplied to the cutting head (e.g., cutting head 114) to increase the depth of the cuts (e.g., vertical cuts 160, undercut fillets 162, fillets 164, chamfers 166, trenches 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved contours 180, trenches 182) into the filament mesh structure (e.g., filament mesh structure 90).

[0079] In some embodiments, this method involves increasing the fluid flow rate of a fluid jet (e.g., fluid jet 150) to increase the depth of cuts (e.g., vertical cuts 160, undercut fillets 162, fillets 164, chamfers 166, trenches 168, through holes 170, blind holes 172, V-shaped channels 174, partial cuts 176, chamfers 178, curved contours 180, trenches 182) into a filament mesh structure (e.g., filament mesh structure 90).

[0080] In some embodiments, cutting a filament mesh structure (e.g., filament mesh structure 90) using a fluid jet (e.g., fluid jet 150) includes positioning the cutting head (e.g., cutting head 114) away from the filament mesh structure (e.g., filament mesh structure 90) so that the cutting head (e.g., cutting head 114) does not come into contact with the filament mesh structure (e.g., filament mesh structure 90).

[0081] In some embodiments, this method includes controlling automation (e.g., automation 116) that supports a cutting head (e.g., cutting head 114) to move the cutting head (e.g., cutting head 114) along a cutting path relative to a filament mesh structure (e.g., filament mesh structure 90).

[0082] In some embodiments, this method includes controlling automation (e.g., automation 116) in at least one degree of freedom to move a cutting head (e.g., cutting head 114) along a cutting path.

[0083] In some embodiments, this method includes controlling automation (e.g., automation 116) with at least three degrees of freedom to move a cutting head (e.g., cutting head 114) along a cutting path.

[0084] In some embodiments, this method includes cutting an entire filament mesh structure (e.g., filament mesh structure 90) via a fluid jet (e.g., fluid jet 150).

[0085] In some embodiments, this method includes partially cutting a filament mesh structure (e.g., filament mesh structure 90) via a fluid jet (e.g., fluid jet 150).

[0086] In some embodiments, the method includes cutting one or more planar surfaces and curved contours (e.g., curved contour 180) within a filament mesh structure (e.g., filament mesh structure 90) via a fluid jet (e.g., fluid jet 150).

[0087] In some embodiments, this method includes cutting one or more of the following within a filament mesh structure (e.g., filament mesh structure 90) via a fluid jet (e.g., fluid jet 150): orthogonal surfaces (e.g., vertical cuts 160), fillets (e.g., undercut fillets 162, fillets 164), chamfers (e.g., chamfers 166), and trenches (e.g., trenches 168).

[0088] Referring to Figure 7, an example of a molding system 200 for forming a filament mesh structure 90 is shown. The molding system 200 is configured to form or shape the filament mesh structure 90 without cutting or severing the filaments 52 of the filament mesh structure 90. The filament mesh structure 90 can be formed or shaped by the molding system 200 alone or in combination with the aforementioned cutting system 100.

[0089] As described above, the manufacturing system 60 produces a filament mesh structure 90 having a specific cross-sectional shape, such as a rectangular cross-section. In some cases, the cross-sectional shape produced by the manufacturing system 60 does not provide the desired profile or seat cushion profile. Furthermore, the filaments 52 of the filament mesh structure 90 output from the manufacturing system 60 are cooled and hardened so that the filaments 52 are relatively hard and no longer in a plastic state, and therefore cannot be formed or molded. Therefore, it may be desirable to change the shape of the filament mesh structure 90 from its original cross-sectional profile (e.g., the cross-sectional profile produced by the manufacturing system 60) to provide one or more depressions, protruding regions, curved regions, etc. As an example, the filament mesh structure 90 or a part thereof is heated and reshaped or reformed to provide one or more depressions 210, an example of which is shown in Figure 10.

[0090] The recesses 210 provided in the filament mesh structure 90 may be elongated channels, holes, indentations, or trenches. The recesses 210 may be provided in any suitable location. For example, the recesses 210 may be provided on the side of the filament mesh structure 90 configured to face the occupant of the seat. As some additional examples, the recesses 210 may be provided where the side bolster contacts the central seating portion of the filament mesh structure 90, and the recesses 210 may extend across the central seating portion, such as front and back or left and right, or a combination thereof. The recesses 210 may be spaced apart from each other or may intersect. The recesses 210 may partially extend into the filament mesh structure 90 but may not fully penetrate it.

[0091] Referring to Figure 7, an example of the molding system 200 is shown. The molding system 200 includes a support surface 220, a molding tool 222, a positioning device 224, a steam subsystem 226, and a control system 228.

[0092] The support surface 220 is configured to support the filament mesh structure 90. The support surface 220 may be a generally flat surface, as shown in Figure 7. Alternatively, the support surface 220 may have a contour. The support surface 220 may be a fixed surface or a movable surface. The support surface 220 may be part of the molding die.

[0093] The molding tool 222 facilitates the formation or molding of the filament mesh structure 90. More specifically, the molding tool 222 is configured to reshape the filament mesh structure 90 to change or alter the shape or cross-section of the filament mesh structure 90 at one or more locations. The molding tool 222 is attached to the positioning device 224.

[0094] The molding tool 222 can be provided in various configurations. These configurations are broadly classified by the method by which the molding tool reshapes the filaments 52 of the filament mesh structure 90. For example, the molding tool can reshape the filament mesh structure 90 by engaging the molding tool with the filament mesh structure 90, by not engaging the molding tool with the filament mesh structure 90, or by a combination of these. Figures 7 to 10, and Figures 11 and 12 show examples of molding tools 222, 222' that engage with at least a portion of the filament 52 and apply force to reshape at least one filament 52 of the filament mesh structure 90. In the configuration shown in Figure 13, the molding tool 222'' does not engage with the filament 52 and apply force to reshape the filament mesh structure 90. In each configuration, the molding tools 222, 222', 222'' include one or more nozzles fluidly connected to the steam subsystem 226.

[0095] Referring to Figures 7 to 10, the molding tool 222 is shown to be positioned on the filament mesh structure 90 and the support surface 220. In Figures 7 and 8, the filament mesh structure 90 is shown with a speckled pattern representing a non-cross-sectional view for clarity and simplicity. In Figures 9 and 10, the filaments of the filament mesh structure 90 are illustrated with randomly drawn lines to represent a cross-sectional view of the filament mesh structure 90, so that the depressions 210 are more clearly visible. The molding tool 222 includes a tool body 230, a heater 232, one or more nozzles 234, one or more nozzle valves 236, or a combination thereof.

[0096] The tool body 230 provides the main structure of the molding tool 222. The tool body 230 is mountable to the positioning device 224 and includes or defines one or more passages 240 that fluidly connect the steam subsystem 226 to the nozzle 234 and nozzle valve 236. For example, the tool body 230 may include a manifold 242 from which the passages 240 can extend. The tool body 230 has molding sides 244.

[0097] The molded side surface 244 faces the filament mesh structure 90 and the support surface 220. In at least one configuration, the molded side surface 244 includes one or more molded features 246. The molded features 246 are configured as projections extending toward the filament mesh structure 90, recesses extending away from the filament mesh structure 90, or a combination thereof. One or more nozzles 234 may have molded features 246.

[0098] The heater 232, if present, is configured to heat the molding side 244 of the molding tool 222. The heater 232 can have any suitable configuration. For example, the heater 232 can be configured as an electric or electrical resistance heater and can circulate a heating fluid through the tool body 230. Alternatively, the heater 232 may be part of a steam subsystem 226. For example, a heating fluid such as steam or water can circulate within the tool body 230 before being sent to one or more nozzles 234. The heat or thermal energy provided to the molding side 244 by the heater 232 raises the temperature of the molding feature 246, which facilitates the modification or reformation of the filament 52, as will be discussed in more detail below.

[0099] One or more nozzles 234 are provided on the tool body 230. The nozzles 234 are fluidly connected to a steam subsystem 226, directing pressurized steam 248 toward the filament mesh structure 90, heating one or more filaments 52 of the filament mesh structure 90 to facilitate the modification or reformation of the filaments 52, as will be discussed in more detail below. The nozzles 234 have at least one orifice from which the steam 248 can be discharged. One or more nozzles 234 may have a molding feature 246. In Figure 7, the nozzles 234 are shown positioned approximately perpendicular to the top surface of the filament mesh structure 90 before reformation. However, the nozzles 234 may be positioned not perpendicular to the top surface of the filament mesh structure 90, or additional nozzles 234 or orifices that can be positioned not perpendicular to the top surface may be provided.

[0100] The nozzle valve 236 controls the flow to one or more associated nozzles 234. In the configuration shown in Figure 7, each nozzle valve 236 is shown as being associated with a single nozzle 234. However, the nozzle valve 236 may be associated with multiple nozzles 234, and some or all of the nozzles 234 may not be fluidically connected to the nozzle valve 236. In some configurations, the nozzle valve 236 is provided with the tool body or within the tool body 230. The nozzle valve 236 is operable between an open position and a closed position. In the open position, the nozzle valve 236 allows flow from the steam subsystem 226 through the nozzle valve 236 to one or more associated nozzles 234. In the closed position, the nozzle valve 236 blocks flow from the steam subsystem 226 through the nozzle valve 236 to one or more associated nozzles 234.

[0101] Referring to Figures 11 and 12, another example of the molding tool 222' is shown. In Figure 11, the filament mesh structure 90 is shown with a speckled pattern representing a non-cross-sectional view for clarity and simplification. In Figure 12, the filaments of the filament mesh structure 90 are illustrated by randomly drawn lines to represent a cross-sectional view of the filament mesh structure. The molding tool 222' can be positioned above the filament mesh structure 90 and may include a tool body 230', a manifold 242', and one or more nozzles 234.

[0102] The tool body 230' is fixedly positioned relative to the manifold 242', the nozzle 234, or both. In at least one configuration, the tool body 230' is positioned away from the nozzle 234 and does not come into contact with it. The tool body 230' is moved or actuated by the positioning device 224. The tool body 230' is moved or actuated at least partially relative to the filament mesh structure 90, as described in more detail below, to apply pressure to reshape one or more filaments 52. The tool body 230' can be configured as a wire, rod, or tube extending entirely or partially across the top surface of the filament mesh structure 90.

[0103] The manifold 242' fluidly connects the steam subsystem 226 to the nozzle 234. For example, the manifold 242' can be configured as a tube or pipe that distributes fluid to the nozzle 234. Furthermore, the manifold 242' can be positioned further away from the top surface of the filament mesh structure 90 than at least a portion of the tool body 230' so that the manifold 242' and / or one or more nozzles 234 do not come into contact with or engage with the filament 52 during reshaping.

[0104] One or more nozzles 234 are fluidically connected to a manifold 242'. One or more nozzle valves 236 may be optionally provided to control the flow of fluid to one or more nozzles 234, as described above. The nozzles 234 may be spaced apart from each other and arranged to provide steam 248 for heating the filament 52 and the tool body 230'.

[0105] Referring to Figure 13, another example of the molding tool 222” is shown. The molding tool 222” is again shown positioned on the filament mesh structure 90. However, it should be understood that the molding tool 222” may be moved to other positions. The molding tool 222” may include one or more nozzles 234 and nozzle valves 236 as described above, but the tool body that can engage with the filament mesh structure 90 may be omitted.

[0106] Referring to Figure 7, the positioning device 224 positions the molding tool 222 relative to the filament mesh structure 90. The positioning device 224 has any suitable configuration. For example, the positioning device 224 may be a linear actuator configured to move the molding tool 222 linearly or along an axis, such as between a retracted position and an extended position. In the retracted position, as shown in Figure 7, the molding tool 222 is separated from, remotely positioned, or spaced apart from the filament mesh structure 90. In the extended position, as shown in Figure 9, the molding tool 222 engages with the filament mesh structure 90 and applies force. The positioning device 224 may also be provided in other configurations. For example, the positioning device may be configured to rotate the molding tool 222 around an axis to engage with or disengage from the filament mesh structure 90. As another example, the positioning device may be configured to move in multiple directions or may have multiple degrees of freedom. An example of such a positioning device is shown in Figure 13, where the positioning device 224" is configured as a robotic manipulator with multiple degrees of freedom.

[0107] The steam subsystem 226 is configured to supply steam 248, or a fluid that becomes steam 248 when discharged from the nozzle 234, to the molding tool 222. Thus, the term “steam” includes any combination of temperature and pressure at which the fluid becomes steam or evaporated fluid after leaving the nozzle. The term “steam” means evaporated water and other evaporated fluids, or evaporated fluids added to water. The steam subsystem 226 has any suitable configuration. In at least one configuration, the steam subsystem 226 includes a fluid source 250, a fluid heater 252, and at least one control valve 254.

[0108] The fluid source 250 is configured to hold or supply a fluid, such as liquid water, which can be converted into steam 248. The fluid source 250 is fluidly connected to the fluid heater 252 and the control valve 254 by any suitable method, such as pipes or hoses.

[0109] The fluid heater 252 is fluidically connected to the fluid source 250. The fluid heater 252 is configured to heat the liquid received from the fluid source 250 so that the fluid becomes a gas or vapor 248 when it exits the nozzle 234 or before it exits the nozzle 234. For example, the fluid heater 252 can heat the liquid so that it becomes a gas after it has passed through the fluid heater 252 and before or after it has passed through the control valve 254.

[0110] The control valve 254 controls the flow of fluid or gas to the molding tool 222. In at least one configuration, the control valve 254 is movable between an open position and a closed position. In the open position, the fluid or gas flows through the control valve 254 to the molding tool 222. In the closed position, the fluid or gas does not flow through the control valve 254.

[0111] The control system 228 monitors and controls various components and subsystems of the molding system 200. For example, the control system 228 may include one or more microprocessor-based control modules or controllers 260 that can control the operation of the molding tool 222, the positioning device 224, the steam subsystem 226, or a combination thereof. Thus, the control system 228 controls the operation of the positioning device 224, the nozzle valve 236, the fluid heater 252, the control valve 254, or a combination thereof.

[0112] Referring to Figure 16, a flowchart of a method for forming the filament mesh structure 90 is shown. This method relates to any of the molding system configurations described above (for example, a molding system 200 that uses individual molding tools 222, 222', 222'' or multiple molding tools 222, 222', 222'' in any combination). This flowchart encompasses three main method steps. This method may have more or fewer steps than those described below, and various steps may be performed in different orders, sequentially, or simultaneously.

[0113] In block 300, the filament mesh structure 90 and the molding tools 222, 222', and / or 222” are aligned such that the molding tools 222, 222', and / or 222” can reshape the filament mesh structure 90 at one or more predetermined positions. The filament mesh structure 90 and the molding tools 222, 222', and / or 222” can be aligned by moving the filament mesh structure 90 with respect to the molding tools 222, 222', and / or 222”; by moving the molding tools 222, 222', and / or 222” with respect to the filament mesh structure 90; or both.

[0114] In block 302, the filament mesh structure 90 is formed by molding tools 222, 222', and / or 222''. The filament mesh structure 90 is formed by molding tools 222, 222', and / or 222'' by spraying vapor 248 onto the filament mesh structure 90. The vapor 248 may be sprayed directly onto the filaments 52 or through an intermediate vapor-permeable layer such as a woven fabric or cloth. Spraying vapor 248 onto the filament mesh structure provides multiple functions.

[0115] Firstly, the steam 248 heats the filament 52, enabling the filament 52 to be reformed or reshaped. More specifically, the thermal energy provided by the steam 248 heats the thermoplastic filament 52 to a temperature that allows the thermoplastic material of the heated filament 52 to be reformed into different shapes. The thermal energy softens or plasticizes the filament 52 without melting it. Thus, the steam 248 is provided to maintain the temperature of the filament 52 below the melting temperature of the thermoplastic material. As an example, the filament 52 may be heated by the steam 248 to a temperature 10°C to 50°C lower than the melting temperature of the thermoplastic material. In this way, the filament 52 is heated in a manner sufficient to allow the filament 52 to be plastically reformed, but insufficient to form new bonds between one filament 52 and another, or between the filament 52 and itself.

[0116] Secondly, the vapor 248 provides a coating or barrier that helps prevent the filament 52 from adhering or sticking to the molding tool 222, 222', and / or 222''. The coating may be a coating of fluid or droplets of fluid that accumulates outside the filament 52. The coating may act as a lubricant or barrier that comes into contact with the molding tool 222, 222', and / or 222'', preventing the filament 52 from bonding to the molding tool 222, 222', and / or 222''.

[0117] Thirdly, depending on the circumstances, the steam 248 exerts sufficient pressure to reshape one or more filaments 52 of the filament mesh structure 90.

[0118] The reformation of the filament mesh structure 90 may be controlled by supplying different amounts of steam 248 to different nozzles 234. For example, a first nozzle valve 236 that controls the flow of steam to a first nozzle 234 may be controlled to discharge a different amount of steam 248 than a second nozzle valve 236 that controls the flow of steam to a second nozzle 234.

[0119] In block 304, the steam flow 248 is turned off, and the positions of the molding tools 222, 222', and / or 222” are reset to accommodate the reshaping of another filament mesh structure 90. The steam flow 248 may be turned off before resetting the positions of the molding tools 222, 222', and / or 222”; while the positions of the molding tools 222, 222', and / or 222” are being reset; or after resetting the positions of the molding tools 222, 222', and / or 222”. Turning off the steam flow 248 allows the temperature of the filament 52 to decrease so that it cannot be reshaped into a different shape without reheating the filament 52.

[0120] More specific examples of method steps related to different molding system configurations are described below.

[0121] Referring to Figure 7, the molding tool 222 is shown in the storage position as described above. The filament mesh structure 90 and the molding tool 222 are aligned so that the molding tool 222 is ready to reshape the filament mesh structure 90 in one or more predetermined positions. The control valve 254, the nozzle valve 236, or both are closed so that the steam 248 is not sprayed by the nozzle 234. In a configuration in which the molding tool 222 includes a heater 232, the heater 232 can heat the molding tool 222 when the steam 248 is not sprayed by the nozzle 234.

[0122] Referring to Figure 8, it is shown that steam 248 is being sprayed by the nozzle 234. Steam 248 is sprayed by the nozzle 234 by opening the control valve 254 and, if one or more nozzle valves 236 are provided. The steam 248 is directed towards one or more filaments 52 of the filament mesh structure 90 to heat the filaments 52 and help prevent the filaments 52 from subsequently bonding to the molding tool 222 as described above.

[0123] Referring to Figure 9, the molding tool 222 engages with the filament mesh structure 90. The molding tool 222 engages with the filament mesh structure 90 by moving the filament mesh structure 90, the molding tool 222, or both, as described above. The movement of the molding tool 222, the filament mesh structure 90, or both can be started before the steam 248 is sprayed at the nozzle 234, after the steam 248 is sprayed at the nozzle 234, or simultaneously with the start of the spraying of steam 248 at the nozzle 234. It is also conceivable that the molding tool 222 engages with the filament mesh structure 90 before the steam 248 is sprayed at the nozzle 234, after the steam 248 is sprayed at the nozzle 234, or simultaneously with the start of the spraying of steam 248 at the nozzle 234.

[0124] In the illustrated configuration, the molding tool 222 engages with the filament mesh structure 90 by moving the molding tool 222 toward the filament mesh structure 90 using a positioning device 224. The filament mesh structure 90 and the molding tool 222 are separated in Figure 9 to better illustrate the molding tool 222 engaging with the filament mesh structure 90. The engagement of the molding tool 222 with the filament mesh structure 90 causes the molding tool 222 to exert force on the filaments 52 softened by the steam 248 and optionally heated molding tool 222. In response to this force, the softened filaments 52 are reshaped by the molding tool 222 and its molding features 246. For example, softened filaments 52 may be reshaped or reformed around the molding features 246, but other filaments 52 that are not engaged by the molding tool 222 or are not sufficiently heated may not be reshaped. An example of filament reshaping 52 is best illustrated with reference to Figures 14 and 15.

[0125] Figure 14 shows a magnified view of a portion of the filament mesh structure 90. Multiple filaments 52 are shown in their initial configuration before reshaping or reforming. The initial configuration may be the configuration provided when the filament mesh structure 90 is first manufactured. For illustrative purposes, a location on one filament 52 is designated as point A, and a location on another filament 52 is designated as point B. Point A is spaced apart from and does not touch point B in Figure 14.

[0126] Figure 15 shows a magnified view of a portion of the filament mesh structure 90 after it has been reshaped or reformed by the molding tools 222, 222', and / or 222”. The filament 52 containing point A has been reformed by the molding tools 222, 222', and / or 222”, such that the filament 52 containing point A moves downward from the illustrated perspective and comes into contact with the filament 52 containing point B. The filament 52 containing point A has been reformed and moved to come into contact with the filament 52 containing point B, but no new bond has been formed between these filaments.

[0127] Referring again to Figure 9, the molding tool 222 engages with or applies force to the filament mesh structure 90 for a period of time sufficient to allow the filament 52 to reshape or reform. For example, the molding tool 222 can engage with the filament mesh structure 90 for about 1 to 10 seconds, but this period may be less than 1 second if the filament 52 is sufficiently heated before engagement, and may be longer than 10 seconds if the filament 52 is not heated before engagement.

[0128] Referring to Figure 10, the molding tool 222 is reset. The molding tool 222 is reset by operating the positioning device 224 to retract the molding tool 222 to the position shown in Figure 7. The flow of steam 248 through the nozzle 234 can be terminated before retracting the molding tool 222, after the molding tool 222 begins to retract, or simultaneously with the start of the molding tool 222's retraction. The flow of steam 248 is terminated by closing the nozzle valve 236, the control valve 254, or both. Stopping the flow of steam 248 before raising the molding tool 222 can reduce energy consumption and help avoid the possibility of continuous heating of the filament 52 and excessive softening or melting of the filament 52.

[0129] The method steps relating to the configurations shown in Figures 11 and 12 are similar to the steps relating to the configurations shown in Figures 7-10. For example, the molding tool 222' can be started in a retracted position with one or more valves closed, such as the control valve 254 and / or the nozzle valve 236, so that steam 248 is not sprayed by the nozzle 234. One or more valves are opened so that steam 248 is sprayed by the nozzle 234. The steam 248 is directed to a position on the filament mesh structure 90 where the molding tool 222' engages with the filament mesh structure 90. Optionally, some of the steam 248 can be directed towards the molding tool 222' to heat it. The steam 248 heats the filament 52 and prevents the filament 52 from binding to the molding tool 222', as described above.

[0130] The molding tool 222 engages with the filament mesh structure 90 by moving the molding tool 222', the filament mesh structure 90, or both. The engagement of the molding tool 222' with the filament mesh structure 90 causes the molding tool 222' to exert force on the filaments 52 that have been softened by the steam 248 and optionally heated by the molding tool 222'. As a result, the softened filaments 52 are reformed by the molding tool 222'. For example, the softened filaments 52 may be reformed or reformed around the molding feature 246', but other filaments 52 not engaged by the molding tool 222' or the reformed filaments 52 are not reformed. The molding tool 222' can engage with the filament mesh structure 90 for a period sufficient to allow the filaments 52 to be reformed or reformed as described above. Finally, the molding tool 222' may be reset by operating the positioning device 224 to terminate the flow of steam 248 through the nozzle 234.

[0131] The forming tool 222' is shown in Figures 11 and 12 having a circular cross-section. However, it should be understood that the forming tool 222' may have a non-circular cross-section or a combination of circular and non-circular cross-sections. For example, a forming tool 222' having a V-shaped cross-section can form a V-shaped channel 174, as shown in Figure 5G. Similarly, the forming tool 222' in Figures 11 and 12 is shown having a straight or linear shape. However, it is conceivable that the forming tool 222' may have a curved or non-linear shape, or a combination of straight and curved segments or straight and non-linear segments.

[0132] Methods relating to the molding system 200 according to several embodiments aim to form a filament mesh structure (e.g., filament mesh structure 90). In various embodiments, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0133] This method involves spraying vapor (e.g., vapor 248) onto a filament mesh structure (e.g., filament mesh structure 90), the filament mesh structure (e.g., filament mesh structure 90) comprising filaments (e.g., filaments 52) of a thermoplastic material, the filaments (e.g., filaments 52) being randomly looped and joined together, and heating at least a portion of the filaments (e.g., filaments 52) by spraying vapor (e.g., vapor 248).

[0134] This method involves engaging a molding tool (e.g., molding tool 222 and / or 222') with a filament (e.g., filament 52) ​​heated by steam (e.g., steam 248), thereby reforming a filament mesh structure (e.g., filament mesh structure 90).

[0135] In some embodiments, the filament (e.g., filament 52) ​​is heated by steam (e.g., steam 248) to a temperature below the melting point of the thermoplastic material.

[0136] In some embodiments, steam (e.g., steam 248) is sprayed onto a filament mesh structure (e.g., filament mesh structure 90) before engaging a molding tool (e.g., molding tool 222 and / or 222') with a filament (e.g., filament 52).

[0137] In some embodiments, when vapor (e.g., vapor 248) is sprayed onto a filament mesh structure (e.g., filament mesh structure 90), a liquid coating accumulates on the filament (e.g., filament 52).

[0138] In some embodiments, a molding tool (e.g., molding tool 222 and / or 222') comes into contact with the liquid coating.

[0139] In some embodiments, the molding tool (e.g., molding tool 222 and / or 222') is heated before it engages with the filament (e.g., filament 52).

[0140] In some embodiments, steam (e.g., steam 248) heats the molding tool (e.g., molding tool 222 and / or 222') while the molding tool is engaged with the filament (e.g., filament 52).

[0141] In some embodiments, spraying steam (e.g., steam 248) includes spraying steam (e.g., steam 248) using a first nozzle (e.g., nozzle 234) and a second nozzle (e.g., nozzle 234), wherein a first nozzle valve (e.g., nozzle valve 236) controls the flow of steam (e.g., steam 248) to the first nozzle (e.g., nozzle 234), and a second nozzle valve (e.g., nozzle valve 236) controls the flow of steam (e.g., steam 248) to the second nozzle (e.g., nozzle 234), and the amount of steam (e.g., steam 248) supplied to the first nozzle (e.g., nozzle 234) using the first nozzle valve (e.g., nozzle valve 236) is different from the amount of steam (e.g., steam 248) supplied to the second nozzle (e.g., nozzle 234) using the second nozzle valve (e.g., nozzle valve 236).

[0142] In some embodiments, the spraying of steam (e.g., steam 248) is terminated and the molding tool (e.g., molding tool 222 and / or 222') is separated from the filament mesh structure (e.g., filament mesh structure 90) after the filament mesh structure (e.g., filament mesh structure 90) has been reformed.

[0143] In some embodiments, steam (e.g., steam 248) heats the molding tool (e.g., molding tool 222 and / or 222') before it engages with the filament (e.g., filament 52), and heats the molding tool (e.g., molding tool 222 and / or 222') while it is engaging with the filament (e.g., filament 52).

[0144] In some embodiments, the atomization of steam (e.g., steam 248) includes atomizing steam (e.g., steam 248) together with a molding tool (e.g., molding tool 222 and / or 222'), the molding tool (e.g., molding tool 222 and / or 222') includes one or more nozzles (e.g., nozzle 234) fluidly connected to a manifold (e.g., 242 and / or 242'), and a tool body (e.g., tool body 230 and / or 230') fixedly positioned relative to the nozzles (e.g., nozzle 234).

[0145] In some embodiments, multiple nozzles (e.g., nozzle 234) do not come into contact with the filament (e.g., filament 52) ​​when spraying steam (e.g., steam 248).

[0146] In some embodiments, engaging a molding tool (e.g., molding tool 222 and / or 222') with a filament (e.g., filament 52) ​​involves at least partially operating the tool body (e.g., tool body 230 and / or 230') within the filament mesh structure (e.g., filament mesh structure 90) to apply pressure that reshapes the filament mesh structure (e.g., filament mesh structure 90).

[0147] In some embodiments, multiple nozzles (e.g., nozzle 234) are separated from the filament mesh structure (e.g., filament mesh structure 90) when the tool body (e.g., tool body 230') is at least partially operated within the filament mesh structure (e.g., filament mesh structure 90).

[0148] Referring to Figure 13, the force is exerted by the steam 248 to reshape the filament 52, rather than by the engagement of the molding tool 222” with the filament 52. The method steps associated with this configuration are similar to those described above. First, the filament mesh structure 90 and the molding tool 222” are aligned so that the molding tool 222” is positioned to reshape the filament mesh structure 90 in one or more predetermined configurations. Next, the steam 248 is sprayed by one or more nozzles 234. The steam 248 may also be sprayed by the nozzles 234 by opening a control valve 254 and one or more nozzle valves 236, if such valves are provided. The steam 248 is directed at one or more filaments 52 of the filament mesh structure 90 to heat the filament 52 for a sufficient amount or duration so that the filament 52 can be reshaped or reformed. The filament 52 is reshaped by the pressure applied by the steam 248, rather than by contact with, engagement with, or direct force applied to the filament 52 with the molding tool 222”.

[0149] The force exerted on one or more filaments 52 by the steam 248 is controlled by the control system 228 by controlling the position of the nozzles 234, controlling the movement of the nozzles 234, controlling the flow (e.g., flow rate) of the steam 248 through one or more nozzles 234, controlling the amount of time the steam 248 is applied to the filaments 52, controlling the number of nozzles or nozzle orifices that spray the steam 248 toward the filaments, or a combination thereof. For example, the amount of force exerted by the steam 248 can be increased by opening the nozzle valves 236 wider to increase the steam flow rate and the amount of force exerted, holding the nozzles 234 over the filaments 52 for a longer time, applying force to the filaments 52 with steam from more nozzles 234, moving the nozzles 234 closer to the filaments 52 to increase the amount of steam 248 pressing against the filaments 52 (rather than spraying over or toward another filament 52), or a combination thereof. Increasing the amount of force applied to the filaments 52 can cause greater movement of the filaments, which can form deeper or wider depressions in the filament mesh structure 90.

[0150] Conversely, the amount of force exerted by the steam 248 can be reduced by closing the valve, opening the nozzle valve 236 less to reduce the steam flow rate and the amount of force exerted, holding the nozzle 234 over the filament 52 for a shorter time, applying force to the filament 52 with steam from fewer nozzles 234, moving the nozzle 234 further away from the filament 52 to reduce the amount of steam 248 pressing against the filament 52, or a combination thereof. Reducing the amount of force applied to the filament can reduce the movement of the filament, which can form shallower or narrower depressions in the filament mesh structure 90. The pressure exerted by the steam can be changed as the molding tool 222" moves.

[0151] In some configurations, the nozzle 234 is moved by a positioning device 224" while spraying steam 248 so that the steam 248 heats and reshapes additional filaments 52 of the filament mesh structure 90. As a result, the travel path of the nozzle 234 can be used to form various contour features on the filament mesh structure 90 without contacting the filament mesh structure 90. The flow of steam 248 is interrupted or temporarily blocked when the nozzle 234 moves over areas of the filament mesh structure 90 that are not being reshaped.

[0152] Methods relating to the molding system 200 according to several embodiments aim to form a filament mesh structure (e.g., filament mesh structure 90). In various examples, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0153] This method involves spraying steam (e.g., steam 248) onto a filament mesh structure (e.g., filament mesh structure 90) using a molding tool (e.g., molding tool 222"), the filament mesh structure (e.g., filament mesh structure 90) consisting of randomly looped and joined filaments (e.g., filaments 52) of thermoplastic material, the molding tool (e.g., molding tool 222") having a nozzle (e.g., nozzle 234) for spraying steam (e.g., steam 248), the steam (e.g., steam 248) heating and pressurizing at least a portion of the filaments (e.g., filaments 52) to reshape the filament mesh structure (e.g., filament mesh structure 90), and the molding tool (e.g., molding tool 222") not engaging with the filament mesh structure (e.g., filament mesh structure 90).

[0154] In some embodiments, reforming the filament mesh structure (e.g., filament mesh structure 90) involves moving a nozzle (e.g., nozzle 234) relative to the filament mesh structure (e.g., filament mesh structure 90) while spraying steam (e.g., steam 248).

[0155] In some embodiments, moving a nozzle (e.g., nozzle 234) while spraying steam (e.g., steam 248) heats and reshapes additional filaments (e.g., filament 52) ​​of the filament mesh structure (e.g., filament mesh structure 90).

[0156] In some embodiments, steam (e.g., steam 248) is sprayed directly onto a filament mesh structure (e.g., filament mesh structure 90).

[0157] In some embodiments, the pressure applied by steam (e.g., steam 248) changes as the molding tool (e.g., molding tool 222") is moved.

[0158] In some embodiments, the molding tool (e.g., molding tool 222") is positioned on a positioning device (e.g., positioning device 224).

[0159] By heating the filament with steam or the like, the filament mesh structure 90 can be reshaped after its initial manufacture. In this way, the filament mesh structure 90 can be reshaped from its initial configuration to another configuration more suitable for seated applications, thereby improving the comfort of the seated occupants. Reshaping is achieved without cutting or removing material from the filament mesh structure 90, thereby reducing or eliminating material removal work and reducing waste. Reshaping can be achieved using steam rather than chemicals or softeners. Furthermore, steam can prevent the filament from sticking to the molding tool without the use of oil or other conventional lubricants, thereby reducing costs and allowing the filament mesh structure to be quickly reshaped into the desired shape.

[0160] Referring to Figures 17 to 23, another example of a cushion (e.g., cushion 50) is shown. In this example, the filament mesh structure 90 of the cushion is folded to produce a desired shape. Folding can be facilitated by forming recesses or trenches in the filament mesh structure 90 using the aforementioned cutting system 100 or molding system 200. Figures 17 to 22 are grouped in pairs, with even-numbered figures being top views and odd-numbered figures being side views.

[0161] Referring to Figures 17 and 18, fragments or blocks of a filament mesh structure 90 that can be manufactured in the manufacturing system 60 are shown. For simplicity, the filament mesh structure 90 is shown to have a substantially rectangular shape and a rectangular cross-section. The filament mesh structure 90 has a plurality of sides, including a first side 400, a second side 402, a third side 404, and a fourth side 406. In this example, the first side 400 is positioned opposite the second side 402, and the third side 404 is positioned opposite the fourth side 406. The third side 404 may be the front, and the fourth side 406 may be the back. The filament mesh structure 90 may also include a first lateral side 408 and a second lateral side 410 positioned opposite the first lateral side 408.

[0162] Referring to Figures 19 and 20, blocks of the filament mesh structure 90 are shown after they have been formed to provide different shapes. The filament mesh structure 90 may be formed by removing material using a cutting system 100, by forming or reforming the filaments of the filament mesh structure 90 using a forming system 200, or both. It is also conceivable that the filament mesh structure 90 may be formed in a die to form or reform the filaments.

[0163] In Figure 19, the periphery of the filament mesh structure 90, as viewed from above, is shown with a curved or contoured shape, as is evident by comparing Figures 17 and 18 with Figures 19 and 20. The curved or contoured shape may include forming or removing material from one or more sides of the filament mesh structure 90. In Figures 19 and 20, the filament mesh structure 90 is shown comprising a plurality of trenches, such as a first trench 420, a second trench 422, a third trench 424, and a fourth trench 426. These trenches may have a linear or nonlinear configuration.

[0164] A first trench 420 and a second trench 422 are shown, formed on the first side 400 and extending partially toward the second side 402. The first trench 420 and the second trench 422 are shown extending from the third side 404 to the fourth side 406.

[0165] The portion of the filament mesh structure 90 positioned between the bottom of the first trench 420 and the second side 402 is called the first foldable connecting segment 430. The first foldable connecting segment 430 includes filaments 52 connecting the first portion 440 of the filament mesh structure 90 to the second portion 442 of the filament mesh structure 90 positioned on the opposite side of the first trench 420 from the first portion 440. In the illustrated configuration, the first portion 440 is the central portion or central seating portion of the filament mesh structure 90. The first foldable connecting segment 430 may have a linear configuration, a nonlinear configuration, or a combination thereof. In the illustrated configuration, the first foldable connecting segment 430 is linear.

[0166] The portion of the filament mesh structure 90 positioned between the bottom of the second trench 422 and the second side 402 is called the second foldable connecting segment 432. The second foldable connecting segment 432 includes a first portion 440 of the filament mesh structure 90 and filaments 52 connecting the first portion 440 to a third portion 444 of the filament mesh structure 90 positioned on the opposite side of the second trench 422. The second foldable connecting segment 432 may have a linear configuration, a nonlinear configuration, or a combination thereof. In the illustrated configuration, the second foldable connecting segment 432 is linear.

[0167] The first trench 420 and the second trench 422 can have any suitable cross-sectional shape. In the illustrated configuration, the first trench 420 and the second trench 422 are generally shown as V-shaped or slit-shaped.

[0168] Referring primarily to Figure 19, if a third trench 424 and a fourth trench 426 are provided, they are shown to be formed on the second side surface 402 and to partially penetrate the filament mesh structure 90 and extend toward the first side surface 400. Optionally, the third trench 424 and the fourth trench 426 may extend toward the first foldable connecting segment 430, the second foldable connecting segment 432, or both.

[0169] It should be understood that the filament mesh structure 90 may be inverted or flipped over from the position shown in Figures 19 and 20 when the filament mesh structure is formed. For example, the filament mesh structure 90 may be positioned with the first side surface 400 facing upward to facilitate access by the cutting system 100, the forming system 200, or both.

[0170] Referring to Figures 21 and 22, the filament mesh structure 90 is shown after folding the filament mesh structure 90 along the first foldable connecting segment 430 and the second foldable connecting segment 432.

[0171] In some configurations, when the second portion 442 is folded along the first foldable connecting segment 430, the second portion 442 is positioned on the first portion 440. When the second portion 442 is folded on the first portion 440, the second portion 442 may be positioned to contact the first portion 440. For example, when the second portion 442 is folded along the first foldable connecting segment 430, the portion of the second side 402 on which the second portion 442 is provided is folded back, and the second portion 442 rotates relative to the first portion 440 so as to contact the portion of the second side 402 on which the first portion 440 is provided. When the second portion 442 is folded in this manner, a seat cushion (e.g., cushions 32 and / or 42) may be generated in which the second portion 442 forms a first side bolster.

[0172] In some configurations, when the third portion 444 is folded along the second foldable connecting segment 432, the third portion 444 is positioned on the first portion 440. When the third portion 444 is folded along the first portion 440, the third portion 444 may be positioned to contact the first portion 440. For example, when the third portion 444 is folded along the second foldable connecting segment 432, the portion of the second side 402 on which the third portion 444 is provided is folded back, and the third portion 444 rotates relative to the first portion 440 so that it contacts the portion of the second side 402 on which the first portion 440 is provided. When the third portion 444 is folded in this manner, a seat cushion (e.g., cushions 32 and / or 42) may be generated in which the third portion 444 forms a second side bolster.

[0173] Although the first part 440 and the second part 442 are shown to rotate upward, this is not intended to be limiting, as the foldable parts can rotate in any suitable direction based on the position of the trench and associated foldable connecting segments. Furthermore, in some configurations, the foldable parts can be folded by a smaller angular distance. For example, they can be folded so that opposite sides of the V-shaped slits engage with each other.

[0174] Referring to Figure 23, the folded portion is secured. For example, the second portion 442 is secured to the first portion 440 after the second portion 442 is folded, thereby holding the second portion 442 in its folded position. Similarly, the third portion 444 is secured to the first portion 440 after the third portion 444 is folded, thereby holding the third portion 444 in its folded position. The securing of the folded portion is represented by the attachment mark 450 in Figure 23. The folded portion, such as the second portion 442 or the third portion 444, can be secured in any suitable way. For example, the attachment mark 450 may represent attachment by chemical or adhesive bonding with a mechanical fastener such as a clip, ring, hook-and-loop fastener, clamp, etc., or it may represent direct bonding of one or more filaments 52 of the folded portion to the first portion 440 by heat bonding or melting one or more filaments 52 such that a new bonding point is formed on the filament 52. It is also possible that the folded portion is not secured.

[0175] It should be understood that trenches or foldable connecting segments may be provided on the opposite side of the filament mesh structure 90 to allow the filament mesh structure 90 to be folded in different directions. Thus, different parts of the cushion may be folded in different planes along different axes or along different sides of the filament mesh structure 90.

[0176] It should also be understood that the cushion (e.g., cushion 50) may be provided by stacking multiple layers of the filament mesh structure 90, and that one or more layers may not have foldable connecting segments. For example, foldable connecting segments may be provided in the topmost filament mesh structure layer, but not in other layers located below or behind the topmost filament mesh structure layer. It should also be understood that the layers may be stacked laterally rather than vertically.

[0177] The cushion (e.g., cushion 32 and / or 42) includes a filament mesh structure (e.g., filament mesh structure 90) comprising filaments (e.g., filament 52) ​​of a thermoplastic material, the filaments (e.g., filament 52) ​​being randomly looped and joined together, and the filament mesh structure (e.g., filament mesh structure 90) has trenches (e.g., trenches 168 and / or 420 and / or 422) extending from a first side (e.g., first side 400) of the filament mesh structure (e.g., filament mesh structure 90) toward a second side (e.g., second side 402) of the filament mesh structure (e.g., filament mesh structure 90), and the second side (e.g., second side 402) is A trench (e.g., trench 168, and / or 420, and / or 422) and a second side (e.g., second side 402) are positioned opposite a first side (e.g., first side 400) and cooperate to form a foldable connecting segment (e.g., foldable connecting segment 430) between them, the foldable connecting segment (e.g., foldable connecting segment 430) connecting a first part (e.g., first part 440) of a filament mesh structure (e.g., filament mesh structure 90) to a second part (e.g., second part 442) of the filament mesh structure (e.g., filament mesh structure 90), the second part (e.g., second part 442) is folded over the first part (e.g., first part 440).

[0178] In some embodiments, a second side surface (e.g., a second side surface 402) of a first portion (e.g., a first portion 440) contacts a second side surface (e.g., a second side surface 402) of a second portion (e.g., a second portion 442).

[0179] In some embodiments, a first portion (e.g., first portion 440) is fixed to a second portion (e.g., second portion 442).

[0180] In some embodiments, the cushion (e.g., cushion 32 and / or 42) is a seat cushion.

[0181] In some embodiments, the second part (e.g., the second part 442) is a side bolster for the cushion (e.g., cushions 32 and / or 42).

[0182] In some embodiments, the first portion (e.g., the first portion 440) at least partially defines the central seating portion of the cushion (e.g., cushions 32 and / or 42).

[0183] Methods according to several embodiments are intended for manufacturing cushions (e.g., cushions 32 and / or 42). In various embodiments, the method may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0184] The method includes the steps of forming trenches (e.g., trenches 168, and / or 420, and / or 422) within a filament mesh structure (e.g., filament mesh structure 90) extending from a first side (e.g., first side 400) of the filament mesh structure (e.g., filament mesh structure 90) toward a second side (e.g., second side 402) of the filament mesh structure (e.g., filament mesh structure 90) that is different from the first side (e.g., first side 400); the steps of having the trenches (e.g., trenches 168, and / or 420, and / or 422) and the second side (e.g., second side 402) cooperate to define a foldable connecting segment (e.g., foldable connecting segment 430) between them; and folding the filament mesh structure (e.g., filament mesh structure 90) along the foldable connecting segment (e.g., foldable connecting segment 430) between them.

[0185] In some embodiments, the foldable connecting segment (e.g., foldable connecting segment 430) is linear.

[0186] In some embodiments, a foldable connecting segment (e.g., foldable connecting segment 430) extends from a third side (e.g., third side 404) of a filament mesh structure (e.g., filament mesh structure 90) to a fourth side (e.g., fourth side 406) of the filament mesh structure (e.g., filament mesh structure 90) that is different from the third side (e.g., third side 404).

[0187] In some embodiments, the third side extends from the first side (e.g., the first side 400) to the second side (e.g., the second side 402).

[0188] In some embodiments, the fourth side (e.g., the fourth side 406) extends from the first side (e.g., the first side 400) to the second side (e.g., the second side 402).

[0189] In some embodiments, a first side (e.g., a first side 400) is positioned opposite a second side (e.g., a second side 402), and a third side (e.g., a third side 404) is positioned opposite a fourth side (e.g., a fourth side 406).

[0190] In some embodiments, a foldable connecting segment (e.g., foldable connecting segment 430) connects a first portion (e.g., first portion 440) of a filament mesh structure (e.g., filament mesh structure 90) to a second portion (e.g., second portion 442) of the filament mesh structure (e.g., filament mesh structure 90), and folding the filament mesh structure (e.g., filament mesh structure 90) along the foldable connecting segment (e.g., foldable connecting segment 430) includes folding the second portion (e.g., second portion 442) on the first portion (e.g., first portion 440).

[0191] In some embodiments, folding a second portion (e.g., a second portion 442) over a first portion (e.g., a first portion 440) includes folding the second portion (e.g., a second portion 442) to bring it into contact with the first portion (e.g., a first portion 440).

[0192] In some embodiments, the second part (e.g., the second part 442) is fixed to the first part (e.g., the first part 440) after the second part (e.g., the second part 442) has been folded, thereby holding the second part (e.g., the second part 442) in the folded position.

[0193] In some embodiments, fixing a second portion (e.g., a second portion 442) to a first portion (e.g., a first portion 440) includes bonding the first portion (e.g., a first portion 440) to the second portion (e.g., a second portion 442).

[0194] In some embodiments, fastening a second portion (e.g., second portion 442) to a first portion (e.g., first portion 440) includes fastening the first portion (e.g., first portion 440) to the second portion (e.g., second portion 442) with a fastener.

[0195] In some embodiments, forming trenches (e.g., trenches 420 and / or 422) in a filament mesh structure (e.g., filament mesh structure 90) involves cutting the filament mesh structure (e.g., filament mesh structure 90).

[0196] Clause 1: A method comprising cutting a filament mesh structure via a fluid jet.

[0197] Clause 2 The method according to Clause 1, wherein a cushion is formed at least partially by cutting a filament mesh structure using a fluid jet.

[0198] Clause 3 The method according to Clause 2, further comprising attaching the cushion to the frame of the seat assembly.

[0199] Clause 4 The method according to Clause 3, further comprising placing the trim cover on top of the cushion and attaching the trim cover to the cushion, frame, or cushion and frame.

[0200] Clause 5 The method according to any one of Clauses 1 to 4, further comprising forming a filament mesh structure with filaments of a thermoplastic material, wherein the filaments are randomly looped and joined together.

[0201] Clause 6 The method according to Clause 5, wherein forming a filament mesh structure comprises extruding a thermoplastic material through a die to form filaments, and then passing the filaments through a funnel.

[0202] Clause 7 The method according to Clause 6, further comprising cutting the filament mesh structure after the filament has passed through the funnel.

[0203] Clause 8 The method according to any one of Clauses 1 to 7, further comprising controlling the travel speed of the cutting head to control the depth of the cut into the filament mesh structure.

[0204] Clause 9 The method according to Clause 8, further comprising reducing the travel speed of the cutting head in order to increase the depth of the cut.

[0205] The method according to clause 8 or 9, further comprising bringing the cutting head closer to the filament mesh structure in order to increase the cutting depth.

[0206] The method according to any one of the provisions of 8 to 10, further comprising increasing the fluid pressure supplied to the cutting head in order to increase the depth of the cut.

[0207] Clause 12 The method of any one of Clauses 8 to 11, further comprising increasing the fluid flow rate of the fluid jet to increase the depth of the cut.

[0208] Clause 13 The method of cutting a filament mesh structure with a fluid jet, comprising positioning the cutting head away from the filament mesh structure so that the cutting head does not come into contact with the filament mesh structure.

[0209] Clause 14 The method according to any one of Clauses 8 to 13, further comprising controlling an automated device supporting the cutting head to move the cutting head along a cutting path relative to the filament mesh structure.

[0210] Clause 15 The method of Clause 14, further comprising controlling the automaton with at least one degree of freedom to move the cutting head along the cutting path.

[0211] Clause 16 The method of Clause 14, further comprising controlling the automaton with at least three degrees of freedom to move the cutting head along the cutting path.

[0212] Clause 17 The method of any one of Clauses 1 to 16, further comprising cutting the entire filament mesh structure via a fluid jet.

[0213] Clause 18 The method of any one of Clauses 1 to 17, further comprising partially cutting the entire filament mesh structure via a fluid jet.

[0214] Clause 19 The method according to any one of Clauses 1 to 18, further comprising cutting one or more planar and curved contours within a filament mesh structure via a fluid jet.

[0215] Clause 20 The method according to any one of Clauses 1 to 19, further comprising cutting one or more orthogonal planes, fillets, chamfers, and trenches in a filament mesh structure via a fluid jet.

[0216] Clause 21 A method for forming a filament mesh structure, the method comprising: spraying vapor onto the filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and joined together, the sprayed vapor heating at least a portion of the filaments; engaging the vapor-heated filaments with a molding tool; and reforming the filament mesh structure by engaging the molding tool.

[0217] Clause 22 The method according to Clause 21, wherein the filament is heated by steam to a temperature below the melting point of the thermoplastic material.

[0218] Clause 23 The method according to Clause 21 or 22, wherein vapor is sprayed onto the filament mesh structure before engaging the forming tool with the filament mesh structure.

[0219] Clause 24 The method according to any one of Clauses 21 to 23, wherein a liquid coating accumulates on the filaments when vapor is sprayed onto the filament mesh structure.

[0220] Clause 25 The method according to any of Clause 24, wherein the molding tool comes into contact with the liquid coating.

[0221] Clause 26 The method according to any one of Clauses 21 to 25, wherein the molding tool is heated before the molding tool engages with the filament.

[0222] Clause 27 The method according to any one of Clauses 21 to 26, wherein the steam heats the molding tool while the molding tool is engaged with the filament.

[0223] Clause 28 The method according to any one of Clauses 21 to 27, wherein the vapor atomization includes vapor atomization from a first nozzle and a second nozzle, a first nozzle valve controls the flow of vapor to the first nozzle, a second nozzle valve controls the flow of vapor to the second nozzle, and the amount of vapor supplied to the first nozzle by the first nozzle valve is different from the amount of vapor supplied to the second nozzle by the second nozzle valve.

[0224] Clause 29 The method according to any one of Clauses 21 to 28, further comprising terminating the vapor spraying after reforming the filament mesh structure and separating the molding tool from the filament mesh structure.

[0225] Clause 30 The method according to any one of Clauses 21 to 29, wherein the steam is heated before the molding tool engages with the filament and while the molding tool is engaged with the filament.

[0226] Clause 31 The method according to any one of Clauses 21 to 30, wherein the vapor atomization includes atomizing vapor together with a molding tool, the molding tool including a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0227] Clause 32 The method according to Clause 31, wherein when vapor is sprayed, multiple nozzles do not come into contact with the filament.

[0228] The method according to Clause 33, wherein engaging the molding tool with the filament includes at least partially moving the tool body into the filament mesh structure and applying pressure to reshape the filament mesh structure.

[0229] Clause 34 The method according to any one of Clauses 31 to 33, wherein when the tool body is operated at least partially within the filament mesh structure, the multiple nozzles are positioned away from the filament mesh structure.

[0230] Clause 35 A method for forming a filament mesh structure, the method comprising spraying vapor onto the filament mesh structure using a forming tool, the filament mesh structure comprising randomly looped and joined filaments of a thermoplastic material, the forming tool having a nozzle for spraying vapor, the vapor heating and pressurizing at least a portion of the filaments to reform the filament mesh structure, the forming tool not engaging with the filament mesh structure, and the spraying.

[0231] Clause 36 The method of Clause 35, wherein the reshaping of the filament mesh structure comprises moving a nozzle over the filament mesh structure while spraying vapor.

[0232] Clause 37 The method according to Clause 36, wherein additional filaments of a filament mesh structure are heated and reformed by moving a nozzle while spraying steam.

[0233] Clause 38 The method according to any one of Clauses 35 to 37, wherein vapor is sprayed directly onto the filament mesh structure.

[0234] Clause 39 The method according to any one of Clauses 35 to 38, wherein the pressure applied by the steam changes as the molding tool moves.

[0235] Clause 40 The molding tool is positioned on a positioning device, as described in any one of Clauses 35 to 39.

[0236] Clause 41 The method according to any one of Clauses 1 to 20, comprising spraying vapor onto the filament mesh structure, wherein the filament mesh structure comprises filaments of a thermoplastic material, the filaments being randomly looped and joined together, the spraying of vapor being to heat, spraying, at least a portion of the filaments, and engaging a molding tool with the vapor-heated filaments, the engaging of the molding tool being to reshape, joining, the filament mesh structure.

[0237] Clause 42 The method according to Clause 42, wherein the filament is heated by steam to a temperature lower than the melting temperature of the thermoplastic material.

[0238] Clause 43 The method according to Clause 41 or 42, wherein steam is sprayed onto the filament mesh structure before engaging the molding tool with the filament mesh structure.

[0239] Clause 44 The method according to any one of Clauses 41 to 43, wherein a liquid coating accumulates on the filament when vapor is sprayed onto the filament mesh structure.

[0240] Clause 45 The method according to Clause 44, wherein the molding tool comes into contact with the liquid coating.

[0241] Clause 46 The method according to any one of Clauses 41 to 45, wherein the molding tool is heated before the molding tool engages with the filament.

[0242] Clause 47 The method according to any one of Clauses 41 to 46, wherein the steam heats the molding tool while the molding tool is engaged with the filament.

[0243] Clause 48 The method according to any one of Clauses 41 to 47, wherein the atomization of vapor includes atomization of vapor by a first nozzle and a second nozzle, wherein a first nozzle valve controls the flow of vapor to the first nozzle, and a second nozzle valve controls the flow of vapor to the second nozzle, and the amount of vapor supplied to the first nozzle by the first nozzle valve is different from the amount of vapor supplied to the second nozzle by the second nozzle valve.

[0244] Clause 49 The method according to any one of Clauses 41 to 48, further comprising terminating the vapor spraying after reforming the filament mesh structure and separating the molding tool from the filament mesh structure.

[0245] Clause 50 The method of any of Clauses 41 to 49, wherein steam is used to heat the molding tool before it engages with the filament and while the molding tool is engaged with the filament.

[0246] Clause 51 The method according to any one of Clauses 41 to 50, wherein spraying vapor includes spraying vapor together with a molding tool, the molding tool comprising a plurality of nozzles fluidly connected to a manifold and a tool body fixedly positioned relative to the plurality of nozzles.

[0247] Clause 52 The method according to Clause 51, wherein when vapor is sprayed, no multiple nozzles come into contact with the filament.

[0248] Clause 53 The method of Clause 51 or 52, wherein engaging a molding tool with a filament involves operating the tool body at least partially within the filament mesh structure to apply pressure that reshapes the filament mesh structure.

[0249] Clause 54 The method according to any one of Clauses 51 to 53, wherein when the tool body is operated at least partially within the filament mesh structure, the multiple nozzles are positioned away from the filament mesh structure.

[0250] Clause 55 The method according to any one of Clauses 1 to 20, further comprising spraying vapor onto a filament mesh structure using a molding tool, wherein the filament mesh structure consists of randomly looped and bonded filaments of a thermoplastic material, the molding tool having a nozzle for spraying vapor, the vapor heating and pressurizing at least a portion of the filaments to reshape the filament mesh structure, and the molding tool not engaging with the filament mesh structure.

[0251] Clause 56 The method according to Clause 55, wherein the reforming of the filament mesh structure comprises moving the nozzle with respect to the filament mesh structure while spraying vapor.

[0252] Clause 57 The method of Clause 56, wherein additional filaments of the filament mesh structure are heated and reformed by moving the nozzle while spraying steam.

[0253] Clause 58 The method according to any one of Clauses 55 to 57, wherein vapor is sprayed directly onto the filament mesh structure.

[0254] Clause 59 The method according to any one of Clauses 55 to 58, wherein the pressure applied by the steam changes as the molding tool is moved.

[0255] Clause 60 The molding tool is positioned on a positioning device, as described in any of Clauses 55 to 59.

[0256] Clause 61 A method for manufacturing a cushion, comprising: forming a trench in a filament mesh structure extending from a first side of the filament mesh structure toward a second side of the filament mesh structure different from the first side; the trench and the second side cooperating to define a foldable connecting segment between the trench and the second side; and folding the filament mesh structure along the foldable connecting segment.

[0257] Clause 62 The method according to Clause 61, wherein the collapsible connecting segment is linear.

[0258] Clause 63 The method according to Clause 61 or 62, wherein a foldable connecting segment extends from a third side of the filament mesh structure to a fourth side of the filament mesh structure that is different from the third side.

[0259] Clause 64 The method of Clause 63, wherein the third aspect extends from the first aspect to the second aspect.

[0260] The method of Article 63 or 64, wherein the fourth aspect extends from the first aspect to the second aspect.

[0261] Clause 66 The method according to any one of Clauses 63 to 65, wherein the first side is positioned opposite the second side, and the third side is positioned opposite the fourth side.

[0262] Clause 67 The method according to any one of Clauses 61 to 66, wherein a foldable connecting segment connects a first portion of a filament mesh structure to a second portion of the filament mesh structure, and folding the filament mesh structure along the foldable connecting segment includes folding the second portion to the first portion.

[0263] Article 68 The method of Article 67, which includes folding the second part into the first part, with the second part being in contact with the first part.

[0264] The method of the

[0265] Clause 70 The method of Clause 69, wherein fixing the second part to the second part includes gluing the first part to the second part.

[0266] Clause 71 Securing the second part to the first part includes the method described in Clause 69 or 70, which involves attaching the first part to the second part with a fastener.

[0267] Clause 72 The method of any one of Clauses 61 to 71, wherein forming a trench in a filament mesh structure includes cutting the filament mesh structure.

[0268] Clause 73 The method according to Clause 72, wherein forming a trench in a filament mesh structure includes cutting the filament mesh structure with a fluid jet.

[0269] Clause 74 The method of Clause 73, wherein cutting a filament mesh structure with a fluid jet forms at least partially a cushion.

[0270] Clause 75 The method of Clause 74, further comprising attaching the cushion to the frame of the seat assembly.

[0271] Clause 76 The method according to Clause 75, further comprising placing a trim cover on top of the cushion and attaching the trim cover to the cushion, frame, or cushion and frame.

[0272] Clause 77 further includes forming a filament mesh structure with filaments of a thermoplastic material, the filaments being randomly looped and joined, by the method according to any one of Clauses 73 to 76.

[0273] Clause 78 The method according to Clause 77, wherein forming the filament mesh structure includes extruding a thermoplastic material through a die to form filaments and then passing the filaments through a funnel.

[0274] Clause 79 The method according to Clause 78, further including cutting the filament mesh structure after the filaments have passed through the funnel.

[0275] Clause 80 The method according to any one of Clauses 73 to 79, further including controlling the moving speed of a cutting head to control the depth of the cut into the filament mesh structure.

[0276] Clause 81 The method according to Clause 80, further including decreasing the moving speed of the cutting head to increase the depth of the cut.

[0277] Clause 82 The method according to Clause 80 or 81, further including moving the cutting head closer to the filament mesh structure to increase the depth of the cut.

[0278] Clause 83 The method according to any one of Clauses 80 to 82, further including increasing the fluid pressure supplied to the cutting head to increase the depth of the cut.

[0279] Clause 84 The method according to any one of Clauses 80 to 83, further including increasing the fluid flow rate of a fluid jet to increase the depth of the cut.

[0280] Clause 85 The method according to any one of Clauses 80 to 84, wherein cutting the filament mesh structure with a fluid jet includes positioning the cutting head at a position away from the filament mesh structure so that the cutting head does not contact the filament mesh structure.

[0281] Article 86. The method according to any one of Articles 80 to 85, further comprising controlling an automatic device that supports a cutting head to move the cutting head along a cutting path with respect to a filament mesh structure.

[0282] Article 87. The method according to Article 86, further comprising controlling automation with at least one degree of freedom to move a cutting head along a cutting path.

[0283] Article 88. The method according to Article 86, further comprising controlling an automatic device with at least three degrees of freedom to move a cutting head along a cutting path.

[0284] Article 89. The method according to any one of Articles 73 to 88, further comprising cutting an entire filament mesh structure through a fluid jet.

[0285] Article 90. The method according to any one of Articles 73 to 88, further comprising partially cutting a filament mesh structure through a fluid jet.

[0286] Article 91. The method according to any one of Articles 73 to 90, further comprising cutting one or more of a planar surface and a curved contour of a filament mesh structure through a fluid jet.

[0287] Article 92. The method according to any one of Articles 73 to 91, further comprising cutting one or more of an orthogonal surface, a fillet, a chamfer, and a trench of a filament mesh structure through a fluid jet.

[0288] Article 93. Forming a trench in a filament mesh structure includes reshaping filaments of the filament mesh structure without cutting the filaments, and is the method according to any one of Articles 61 to 71.

[0289] The method according to Clause 93, wherein forming a trench is the process of spraying vapor onto a filament mesh structure, the filament mesh structure comprising filaments of a thermoplastic material, the filaments being randomly looped and joined together, the sprayed vapor heating at least a portion of the filaments, and engaging the vapor-heated filaments with a molding tool, the engagement of the molding tool forming a trench.

[0290] Clause 95 The method according to Clause 94, wherein the filament is heated by steam to a temperature below the melting point of the thermoplastic material.

[0291] Clause 96 The method according to Clause 94 or 95, wherein vapor is sprayed onto the filament mesh structure before the molding tool engages with the filament.

[0292] Clause 97 The method according to any one of Clauses 94 to 96, wherein a liquid coating accumulates on the filament when vapor is sprayed onto the filament mesh structure.

[0293] Clause 98 The method according to Clause 97, wherein a molding tool comes into contact with a liquid coating.

[0294] Clause 99 The method of any of Clauses 94 to 98, wherein the molding tool is heated before the molding tool engages with the filament.

[0295] Clause 100 The method according to any one of Clauses 94 to 99, wherein steam heats the molding tool while the molding tool is engaged with the filament.

[0296] Clause 101: The method according to any one of Clauses 94 to 100, wherein the steam spraying includes the steam spraying by the first nozzle and the second nozzle, the first nozzle valve controls the steam flow to the first nozzle, the second nozzle valve controls the steam flow to the second nozzle, and the amount of steam supplied to the first nozzle by the second nozzle valve is different from the amount of steam supplied to the second nozzle by the second nozzle valve.

[0297] Clause 102: The method according to any one of Clauses 94 to 101, further including terminating the steam spraying and separating the molding tool from the filament mesh structure after reforming the filament mesh structure.

[0298] Clause 103: The method according to any one of Clauses 94 to 102, wherein the steam heats the molding tool before the molding tool engages with the filament and heats the molding tool while the molding tool is engaged with the filament.

[0299] Clause 104: The method according to any one of Clauses 94 to 103, wherein the steam spraying includes spraying steam together with the molding tool, and the molding tool includes a plurality of nozzles fluid-connected to a manifold and a tool body fixedly arranged with respect to the plurality of nozzles.

[0300] Clause 105: The method according to Clause 104, wherein the plurality of nozzles do not contact the filament during the steam spraying.

[0301] Clause 106: The method according to Clause 104 or 105, wherein engaging the molding tool with the filament includes applying a pressure to reform the filament mesh structure by operating the tool body at least partially within the filament mesh structure.

[0302] Clause 107: The method according to any one of Clauses 104 to 106, wherein when the tool body is operated at least partially within the filament mesh structure, the plurality of nozzles are arranged away from the filament mesh structure.

[0303] The method according to Clause 108, wherein forming a trench comprises spraying vapor onto a filament mesh structure using a forming tool, the filament mesh structure consisting of randomly looped and bonded filaments of thermoplastic material, the forming tool having a nozzle for spraying vapor, the vapor heating and pressurizing at least a portion of the filaments to reshape the filament mesh structure to form a trench, and the forming tool not engaging with the filament mesh structure.

[0304] Clause 109 The method of Clause 108, wherein the reshaping of the filament mesh structure comprises moving a nozzle with respect to the filament mesh structure while spraying vapor.

[0305] Clause 110 A method according to Clause 109 for heating and reforming additional filaments of a filament mesh structure by moving a nozzle while spraying vapor.

[0306] Clause 111 The method according to any one of Clauses 108 to 110, wherein vapor is sprayed directly onto a filament mesh structure.

[0307] Clause 112 The method according to any one of Clauses 108 to 111, wherein the pressure applied by steam changes as the molding tool is moved.

[0308] Clause 113 The method according to any one of Clauses 108 to 112, wherein the molding tool is positioned on a positioning device.

[0309] Clause 114 A cushion comprising a filament mesh structure having filaments of a thermoplastic material, wherein the filaments are randomly looped and joined together, the filament mesh structure has a trench extending from a first side of the filament mesh structure toward a second side of the filament mesh structure, the second side being positioned opposite to the first side, the trench and the second side cooperating to form a foldable connecting segment between them, the foldable connecting segment connecting the first portion of the filament mesh structure to the second portion of the filament mesh structure, the second portion being folded over the first portion.

[0310] Clause 115 The cushion as described in Clause 114, wherein the second side of the first part is in contact with the second side of the second part.

[0311] Clause 116 The cushion described in Clause 114 or 115, wherein the first part is fixed to the second part.

[0312] Clause 117 A cushion as described in any of Clauses 114 to 116, wherein the cushion is a seat cushion.

[0313] Clause 118 A cushion as described in any of Clause 116, wherein the second part is a side bolster of the seat cushion.

[0314] Clause 119: The cushion according to Clause 117 or 118, wherein the first part at least partially defines the central seating portion of the cushion.

[0315] Clause 120: A cushion manufactured by any method described in Clauses 1 through 20.

[0316] Clause 121: A cushion manufactured by any method described in Clauses 21 through 34.

[0317] Clause 122: A cushion manufactured by any method described in Clauses 35 through 40.

[0318] Clause 123: A cushion manufactured by any method described in Clauses 41 through 54.

[0319] Clause 124: A cushion manufactured by any method described in Clauses 55 through 60.

[0320] Clause 125: A cushion manufactured by any method described in Clauses 61 through 113.

[0321] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terms used in this specification are descriptive rather than limiting, and it should be understood that various modifications can be made without departing from the spirit and scope of the invention. Furthermore, features of various embodiments can be combined to form further embodiments of the invention.

Claims

1. A method for manufacturing and molding a filament mesh structure (90), Cutting a filament mesh structure (90) via a fluid jet (150) to form at least partially cushions (32, 42, 50), wherein an automated device (116) is controlled to control the movement speed of a cutting head (114) associated with the fluid jet (150) to control the depth of the cut into the filament mesh structure (90), and the movement of the cutting head (114) is controlled in at least three degrees of freedom to move the cutting head (114) along the cutting path relative to the filament mesh structure (90), and cutting the filament mesh structure (90), The cushions (32, 42, 50) are attached to the frame (150) of the seat assembly (10). A method comprising placing trim covers (34, 44) on the cushions (32, 42, 50), and attaching the trim covers (34, 44) to the cushions (32, 42, 50), the frame (150), or the cushions (32, 42, 50) and the frame (150).

2. The method according to claim 1, comprising forming the filament mesh structure (90) with filaments (52) of a thermoplastic material, wherein the filaments (52) are randomly looped and joined together.

3. The method according to claim 2, wherein forming the filament mesh structure (90) includes extruding the thermoplastic material through a die to form the filaments (52), and then passing the filaments (52) through a funnel.

4. The method according to claim 3, further comprising cutting the filament mesh structure (90) after the filament (52) has passed through the funnel.

5. The method according to claim 1, further comprising reducing the travel speed of the cutting head (114) in order to increase the depth of the cut.

6. The method according to claim 1, further comprising bringing the cutting head (114) closer to the filament mesh structure (90) in order to increase the depth of the cut.

7. The method according to claim 1, further comprising increasing the fluid pressure supplied to the cutting head (114) in order to increase the depth of the cut.

8. The method according to claim 1, further comprising increasing the fluid flow rate of the fluid jet (150) to increase the depth of the cut.

9. The method according to claim 1, wherein cutting the filament mesh structure (90) with the fluid jet (150) includes positioning the cutting head (114) away from the filament mesh structure (90) so that the cutting head (114) does not come into contact with the filament mesh structure (90).

10. The method according to claim 1, further comprising controlling the automatic device (116) with at least one degree of freedom to move the cutting head (114) along the cutting path.

11. The method according to claim 1, further comprising cutting the entire filament mesh structure (90) via the fluid jet (150).

12. The method according to claim 1, further comprising partially cutting the filament mesh structure (90) via the fluid jet (150).

13. The method according to claim 1, further comprising cutting one or more planar and curved contours (180) within the filament mesh structure (90) via the fluid jet.

14. The method according to claim 1, further comprising cutting one or more orthogonal planes (160), fillets (162, 164), chamfers (168, 182), and trenches (166, 178) in the filament mesh structure (90) via the fluid jet.

15. A cushion (32, 42, 50) manufactured by the method described in any one of claims 1 to 14.

Images