Seat assembly, fixture, and method of manufacture

Abstract

A fixture includes a base comprising a contour. The contour is operable to receive and is complimentary to a profile of an exterior surface of a filament mesh member comprising a set of filaments of thermoplastic material. The contour is operable to engage the exterior surface of the filament mesh member during an annealing process to maintain a preformed shape of the exterior surface of the filament mesh member.

Description

21866-US-lSEAT ASSEMBLY, FIXTURE, AND METHOD OF MANUFACTURECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional application Serial No.63 / 719,895, filed November 13, 2024, the disclosure of which is hereby incorporated in its entirety by reference herein.TECHNICAL FIELD

[0002] This relates to fixtures for seat assembly cushions comprising filament mesh structures and a method of manufacture.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 is a perspective view of an example of a seat assembly including a filament mesh structure;

[0004] Figure 2 is schematic view of an example of a manufacturing system for making the filament mesh structure;

[0005] Figure 3A is an exploded view of examples of a trim cover and a cushion, the cushion comprising a filament mesh structure;

[0006] Figure 3B is a magnified view of area 3B from Figure 3A;

[0007] Figures 4 is a perspective view of a first embodiment of a fixture that is operable to receive the filament mesh structure;

[0008] Figure 5 is a perspective view of a base portion of the first embodiment of the fixture that is operable to receive the filament mesh structure;21866-US-l

[0009] Figure 6 is a perspective view of a second embodiment of the fixture that is operable to receive the filament mesh structure with the second embodiment of the fixture in a closed condition;

[0010] Figure 7 is a perspective view of the second embodiment of the fixture that is operable to receive the filament mesh structure with the second embodiment of the fixture in an open condition;

[0011] Figure 8 is a perspective view of a third embodiment of the fixture that is operable to receive the filament mesh structure with the third embodiment of the fixture in a closed condition;

[0012] Figures 9 and 10 are perspective views of a fourth embodiment of the fixture that is operable to receive the filament mesh structure; and

[0013] Figure 11 is a flowchart illustrating a method for processing the filament mesh structure.DETAILED DESCRIPTION

[0014] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well- known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0015] It is to be understood that the disclosed embodiments are merely exemplary and that various and alternative forms are possible. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but21866-US-lmerely as a representative basis for teaching one skilled in the art to variously employ embodiments according to the disclosure.

[0016] One or more” includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.[0017| It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0018] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a” and “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and / or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0019] As used herein, the term “if’ is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.21866-US-l

[0020] Referring to Figure 1, an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly, such as for a land vehicle like a car, truck, bus, or the like, or for a non-land vehicle like aircraft or watercraft. For example, a seat assembly 10 for a land vehicle may be shaped and sized as a front row driver or passenger seat, a second, third, or other rear row seat, and may include bucket-style seats as shown, bench-style seats, or other seat styles. Furthermore, the seat assembly 10 may be a non-stowable seat or a stowable seat that may be foldable and stowable in a cavity in the vehicle floor. Additionally, the seat assembly 10 may be configured for non-vehicle applications such as furniture.

[0021] In the configuration shown in Figure 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated 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 stool.

[0022] The seat bottom 20 is configured to receive a seated occupant and support the pelvis and thighs of the seat occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0023] 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, polymeric material, fiber reinforced polymeric material, or combinations thereof. In some configurations, the seat bottom frame 30 includes a panel, seat pan, suspension mat, or suspension wires upon which the cushion 32 is disposed.

[0024] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat bottom frame 30. The cushion 32 and associated methods of manufacture will be discussed in more detail below.

[0025] The trim cover 34 covers at least a portion of the cushion 32. In addition, the trim cover 34 provides one or more visible exterior surfaces of the seat bottom 20. The seat occupant may be disposed on the trim cover 34 when seated upon the seat assembly 10. The trim cover 34 is made of any suitable material or materials, such as fabric, leather, leatherette, vinyl, or combinations thereof. The trim cover 34 may include a plurality of trim panels that are assembled21866-US-lin any suitable manner, such as by fusing or stitching. The trim cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may include trim attachment features that are attached to the seat bottom frame 30, the cushion 32, or both, to inhibit removal of the trim cover 34 and help conform the trim cover 34 to the contour of the seat bottom frame 30, the cushion 32, or both.

[0026] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and near the rear side of the seat bottom 20. The seat back 22 extends in a generally upward direction away from the seat bottom 20. In some configurations, the seat back 22 is mounted to the seat bottom 20 and may be pivotable with respect to the seat bottom 20. In other configurations, the seat back 22 is not mounted to the seat bottom 20. For instance, a vehicle seat back may be mounted 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 head restraint 46.

[0027] 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, polymeric material, fiber reinforced polymeric material, or combinations thereof. In some configurations, the seat back frame 40 includes a panel, pan, suspension mat, or suspension wires upon which the cushion 42 is disposed. It is also contemplated that the seat back frame 40 may be integrally formed with the seat bottom frame 30 in some configurations.

[0028] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be separate from the cushion 32 of the seat bottom 20. The cushion 42 and associated methods of manufacture will be discussed in more detail below.

[0029] The trim cover 44 covers at least a portion of the cushion 42. In addition, the trim cover 44 provides one or more visible exterior surfaces of the seat back 22. The seat occupant may be disposed on the trim cover 44 when seated upon the seat assembly 10. The trim cover 44 is made of any suitable material or materials, such as fabric, leather, leatherette, vinyl, or21866-US-lcombinations thereof. The trim cover 44 may include one trim panel or a plurality of trim panels that are assembled in any suitable manner, such as by fusing 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 attachment features that are attached to the seat back frame 40, the cushion 42, or both, to inhibit removal of the trim cover 44 and help conform the trim cover 44 to the contour of the seat back frame 40, the cushion 42, or both.

[0030] The head restraint 46, if provided, is configured to support the head of a seat occupant. The head restraint 46 is disposed at the top of the seat back 22 or at an end of the seat back 22 that is disposed opposite the seat bottom 20. The head restraint 46 may be moveable in one or more directions with respect to the seat back 22 or may be integrally formed with the seat back 22.

[0031] Referring to Figure 2, the material supply 70 holds material stock that is to be extruded, such as solid beads, flakes, granules, pellets, or powder made of the material. In some configurations, the material supply 70 is configured as a container or hopper. The material supply 70 provides material stock to the extruder 72.

[0032] The extruder 72 melts the material stock and extrudes the material stock into a set of filaments 52. The extruder 72 may have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and heating elements. Rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction generated as the screw rotates. The material exits the barrel under pressure and in a molten state and is transported under pressure to a die 80 of the extruder 72.

[0033] The die 80, which may also be referred to as a die plate or extrusion die, has multiple through holes or filament forming openings through which the molten material passes. A single filament 52 is extruded from each through hole. The filaments 52 fall downward from the die 80 under the force of gravity into the funnel 74.

[0034] The funnel 74 consolidates or groups the filaments 52 into a more compact arrangement in which the filaments bend, curl, or loop and a filament 52 contacts and bonds to at least one other filament 52. The funnel 74 has an inlet opening or funnel inlet and an outlet opening21866-US-lor funnel outlet that is smaller than the funnel inlet. Individual separated filaments 52 enter the funnel inlet. The filaments 52 bend, curl, or loop and move into contact as they accumulate. The filaments 52 move through the funnel 74 toward the funnel outlet. Some filaments may slide along the funnel 74 or an intervening sheet that is disposed on the funnel 74 as the filaments move toward the funnel outlet. Bonds are formed between filaments 52 at the points of contact while openings or voids between filaments 52 are present at other locations where one filament 52 does not contact or bond to another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter the cooling tank 76. For convenience in reference, the bonded filaments 52 are referred to as a mesh member or a filament mesh structure 90.

[0035] The cooling tank 76 holds a liquid, such as water or a mixture of water and another fluid. The liquid in the cooling tank 76 helps support the entangled and bonded filaments 52 to limit further compacting or consolidation of the filaments 52 into a less open or less porous arrangement and maintains a desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance that can result in additional bending, curling, or looping of the filaments 52 adjacent to the surface of the liquid or within the funnel 74 to further build the filament mesh structure 90. The liquid also cools the filaments 52 when the filaments 52 are in the liquid. For instance, the liquid cools the filaments 52 from the outside to solidify the filaments 52 and prevent the filaments 52 from bonding at additional locations. At this point, the filaments 52 are relatively stiff and no longer in a plastic state and thus generally maintain a shape and are not moldable or reformable without being reheated.

[0036] The material handling subsystem 78 transports the filament mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that help move the filament mesh structure 90 through the liquid and out of the liquid. In some configurations, a tractor conveyor 92 is provided in the cooling tank 76 to help pull the filament mesh structure 90 away from the funnel 74 and to counter buoyancy of the filaments 52.

[0037] One or more other rollers, such as roller 94, keep the filament mesh structure 90 submerged in the liquid and guide the filament mesh structure 90 through the cooling tank 76. For example, the roller 94 may guide the filament mesh structure 90 toward a conveyor belt 96 and shaker table 98 that are disposed outside of the cooling tank 76. The shaker table 98 shakes the21866-US-lfilament mesh structure 90 while it is on the conveyor belt 96 to remove liquid. Alternatively or in addition, the filament mesh structure 90 may be squeezed to remove liquid, air may be blown toward the filament mesh structure 90 to help remove liquid from the filament mesh structure 90, or both. It is also contemplated that the filament mesh structure 90 may also be allowed to drip dry, or dry in ambient air.

[0038] 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 provided after exiting the cooling tank 76 to cut the filament mesh structure 90 into individual pieces or blanks for individual cushions. Such processing is conducted by a cutting subsystem of the manufacturing system 60. The cutting system may be of any suitable type. For instance, the cutting system may employ a blade, knife, hot knife, saw, fluid jet, or the like to cut the filaments 52 of the filament mesh structure 90 into a blank. The cutting system may be used to shape or contour the blank. It is also contemplated that a blank may be further shaped or contoured with other manufacturing processes, such as molding of the entire blank or a portion thereof.

[0039] Referring to Figures 3 A and 3B, an example of a cushion 50 is shown. The cushion in generically designated with reference number 50 for convenience in reference. It is to be understood that the structure and description of the cushion 50 is applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0040] The cushion 50 is a non-foam component or includes at least one non-foam component. The non-foam component is primarily referred to as a mesh member but may also be referred to as a stranded member, looped member, entangled member, filament mesh structure, mesh structure, stranded mesh, looped mesh, entangled mesh, or mesh cushion. The cushion 50 is described below in the context of a cushion 50 that does not include foam material. In this context, the cushion 50 is made of filaments 52 of polymeric material that are randomly looped, bent, curled, or entangled and are bonded together. A filament 52 is directed bonded to another filament 52 rather than being indirectly bonded with a resin or other intermediate material.

[0041] The filaments 52, which may also be referred to as strands or threads, are made of any suitable material or materials. In some configurations, the filaments 52 are made of a21866-US-lpolymeric material or thermoplastic material, such as a thermoplastic resin that is polyamide- based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based, or combinations thereof. As one example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). The filament material may be recyclable unlike foam material or more easily recycled than foam material. It is also contemplated that a filament 52 may comprise reinforcement fibers and that the reinforcement fibers may not be made of a thermoplastic material.

[0042] In some configurations, a filament 52 may be a monofilament that is made of a single material. In some configurations, a filament 52 is made of multiple materials. As an example, a filament 52 made of multiple materials may include a core that is made of a first thermoplastic material and a sheath that encircles the core and is made of a second thermoplastic material that differs from the first thermoplastic material. It is contemplated that the cushion 50 may include a combination of monofilaments and filaments that are made of multiple materials and are not monofilaments.

[0043] Filaments 52 that are randomly looped, bent, looped, curled, or entangled are bonded together where one filament 52 contacts another filament 52, thereby resulting in a lightweight, air permeable cushion (e.g., cushion 32 and / or 42) or mesh structure having openings or voids between the filaments 52. An example of a manufacturing system 60 of making a cushion or filament mesh structure is shown in Figure 2. In this example, the manufacturing system 60 includes a material supply 70, an extruder 72, and a funnel 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0044] Referring to Figure 3 A, an exploded view of a portion of the seat assembly 10 is shown that includes an example of the cushion 50 and an example of a trim cover 100. The trim cover 100 may be made from a cloth, textile, fabric material. The trim cover 100 may also referred to as a sheet or cloth cover. The cushion 50 comprises the filament mesh structure 90. In Figure 3A, the cushion 50 is illustrated without depicting individual filaments 52 of the filament mesh structure 90 for clarity. In some configurations, the cushion 50 has a contoured exterior side 110. The contoured exterior side 110 may have a partially or completely nonplanar profile and may include one or more curved surfaces or curved regions. In some configurations, the contoured21866-US-lexterior side 110 is concave or partially concave. The contoured exterior side 110 faces toward the trim cover 100. Moreover, the contoured exterior side 110 may face toward a seat occupant. The contoured exterior side 110 may contact a portion of the trim cover 100 in one or more regions.

[0045] The trim cover 100 is generically designated with reference number 100 for convenience in reference. It is to be understood that the trim cover 100 may be the trim cover 34 of the seat bottom 20 or the trim cover 44 of the seat back 22 as previously described. A portion of the trim cover 100 is shown in Figure 3 A to make other features in this figure more visible. The trim cover 100 is disposed over the cushion 50 comprising the filament mesh structure 90 and may generally follow the curvature or contour of the cushion 50 when secured thereto. The trim cover 100 and the cushion may collectively form a manufactured product such as the vehicle seat bottom 20 or the vehicle seat back 22. A cross section of the annealed mesh member 90 may comprise a varying dimension (e.g., a varying width, height, or thickness).

[0046] Referring to Figures 3-5, a first embodiment of a fixture 200 that is operable to receive the filament mesh structure 90 is illustrated. More specifically, the fixture 200 may be operable to receive the cushion 50 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes, such as molding of the entire blank (e.g., the filament mesh structure 90 before being formed into the cushion 50) or a portion thereof.

[0047] The fixture 200 may comprise two removably interconnecting components, such as a bottom or base 202 and a top, cap, or lid 204. The base 202 may comprise a lower portion of the fixture 200. The base 202 may include a first contour 206. The first contour 206 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to a first region 208 of the filament mesh structure 90. The first region 208 may more specifically be a front side, back side, lateral side, bottom side, or top side of the seat bottom cushion or seat back cushion (e.g., cushion 50) that is formed from the filament mesh structure 90. More specifically, the first contour 206 may be operable to receive and may be complimentary to a profile 210 of an exterior surface 212 of the filament mesh structure 90 along the first region 208. The profile 210 may be referred to as an exterior profile.

[0048] The first contour 206 is operable to engage the first region 208, or more specifically the profile 210 of the exterior surface 212 along the first region 208 during an annealing process21866-US-l(e.g., a heat-treating process) to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the filament mesh structure 90 along the first region 208. More specifically the first contour 206 may be operable to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the cushion 50 along the first region 208 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50. During the annealing process, the molecules of the filament mesh structure 90 may become substantially aligned and uniform. The annealing increases the crystallinity of the filament mesh structure 90 so the filament mesh structure 90 is more stable under high heat and compression conditions. While the stiffness of the filament mesh structure 90 increases during the annealing (e.g., a stiffness of the annealed mesh member 90 is greater than a stiffness of a non-annealed mesh member), the firmness of the filament mesh structure 90 may or may not change.

[0049] The lid 204 may be removably disposable on the base 202. The lid 204 may include a second contour 214. The second contour 214 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to a second region 216 of the filament mesh structure 90. The first contour 206 and the second contour 214 may be portions of a single contour. The second region 216 may more specifically be a front side, back side, lateral side, bottom side, or top side of the seat bottom cushion or seat back cushion (e.g., cushion 50) that is formed from the filament mesh structure 90. The first region 208 and the second region 216 may comprise an entirety of the filament mesh structure 90, or more specifically the cushion 50. The second contour 214 may be operable to receive and may be complimentary to the profile 210 of the exterior surface 212 of the filament mesh structure 90 along the second region 216.

[0050] The second contour 214 is operable to engage the second region 216, or more specifically the profile 210 of the exterior surface 212 along the second region 216 during the annealing process to maintain a preformed shape of the second region 216 and / or exterior surface 212 of the filament mesh structure 90 along the second region 216. More specifically, the second contour 214 may be operable to maintain a preformed shape of the second region 216 and / or exterior surface 212 of the cushion 50 along the second region 216 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50.21866-US-l

[0051] The base 202 and lid 204 may each define orifices 218 to facilitate air flow to the filament mesh structure 90, or more specifically the cushion 50, during the annealing process. Outer peripheries 220 of the base 202 and the lid 204 may define or include opposing sloped regions 222 that are operable to locate and position the lid 204 onto and relative to the base 202.

[0052] Referring to Figures 6-7, a second embodiment of a fixture 300 that is operable to receive the filament mesh structure 90 is illustrated. More specifically, the fixture 300 maybe operable to receive the cushion 50 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes, such as molding of the entire blank (e.g., the filament mesh structure 90 before being formed into the cushion 50) or a portion thereof.

[0053] The fixture 300 may comprise two removably interconnecting components, such as a bottom or base 302 and a top, cap, or lid 304. The base 302 may comprise a lower portion of the fixture 300. The base 302 may include a first contour 306. The first contour 306 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to the first region 208 of the filament mesh structure 90. More specifically, the first contour 306 may be operable to receive and may be complimentary to the profile 210 of the exterior surface 212 of the filament mesh structure 90 along the first region 208.

[0054] The first contour 306 is operable to engage the first region 208, or more specifically the profile 210 of the exterior surface 212 along the first region 208 during an annealing process (e g., a heat-treating process) to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the filament mesh structure 90 along the first region 208. More specifically the first contour 306 may be operable to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the cushion 50 along the first region 208 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50.

[0055] The lid 304 may be removably disposable on the base 302. The lid 304 may include a second contour 314. The second contour 314 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to the second region 216 of the filament mesh structure 90. The first contour 306 and the second contour 314 may be portions of a single contour. The second contour 314 may be operable to receive and may be21866-US-lcomplimentary to the profile 210 of the exterior surface 212 of the filament mesh structure 90 along the second region 216.

[0056] The second contour 314 is operable to engage the second region 216, or more specifically the profile 210 of the exterior surface 212 along the second region 216 during the annealing process to maintain a preformed shape of the second region 216 and / or exterior surface 212 of the filament mesh structure 90 along the second region 216. More specifically, the second contour 314 may be operable to maintain the preformed shape of the second region 216 and / or exterior surface 212 of the cushion 50 along the second region 216 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50.

[0057] The base 302 and lid 304 may each define orifices 318 to facilitate air flow to the filament mesh structure 90, or more specifically the cushion 50, during the annealing process. One of the base 302 or the lid 304 may define recessed regions 322 along or proximate to the outer periphery 320 of the base 302 or lid 304. The other of the base 302 or the lid 304 may include projections 324 extending from the other of the base 302 or the lid 304 along or proximate to the outer peripheries 320 of the other of base 302 or lid 304. The projections 324 are operable to engage the recessed regions 322 to locate and position the lid 304 onto and relative to the base 302.

[0058] Locators 326, such a locator pins, may be disposed on one of the base 302 or the lid 304. The locators 326 may be operable to engage the other of the base 302 or the lid 304 to locate and position the lid 304 onto and relative to the base 302. The other of the base 302 or the lid 304 may more specifically define orifices 328 that operable to receive the locators 326 to locate and position the lid 304 onto and relative to the base 302.

[0059] Referring to Figures 8, a third embodiment of a fixture 400 that is operable to receive the filament mesh structure 90 is illustrated. More specifically, the fixture 400 maybe operable to receive the cushion 50 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes, such as molding of the entire blank (e.g., the filament mesh structure 90 before being formed into the cushion 50) or a portion thereof.21866-US-l

[0060] The fixture 400 may comprise two removably interconnecting components, such as a bottom or base 402 and a top, cap, or lid 404. The base 402 may comprise a lower portion of the fixture 400. The base 402 may include a first contour 406. The first contour 406 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to the first region 208 of the filament mesh structure 90. More specifically, the first contour 406 may be operable to receive and may be complimentary to the profile 210 of the exterior surface 212 of the filament mesh structure 90 along the first region 208.

[0061] The first contour 406 is operable to engage the first region 208, or more specifically the profile 210 of the exterior surface 212 along the first region 208 during an annealing process (e.g., a heat-treating process) to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the filament mesh structure 90 along the first region 208. More specifically the first contour 406 may be operable to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the cushion 50 along the first region 208 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50.

[0062] The lid 404 may be removably disposable on the base 402. The lid 404 may include a second contour 414. The second contour 414 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to the second region 216 of the filament mesh structure 90. The first contour 406 and the second contour 414 may be portions of a single contour. The second contour 414 may be operable to receive and may be complimentary to the profile 210 of the exterior surface 212 of the filament mesh structure 90 along the second region 216.

[0063] The second contour 414 is operable to engage the second region 216, or more specifically the profile 210 of the exterior surface 212 along the second region 216 during the annealing process to maintain a preformed shape of the second region 216 and / or exterior surface 212 of the filament mesh structure 90 along the second region 216. More specifically, the second contour 414 may be operable to maintain the preformed shape of the second region 216 and / or exterior surface 212 of the cushion 50 along the second region 216 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50.21866-US-l

[0064] The base 402 and lid 404 may each define orifices 418 to facilitate air flow to the filament mesh structure 90, or more specifically the cushion 50, during the annealing process. Outer peripheries 420 of the base 402 and the lid 404 may define or include opposing sloped regions 422 that are operable to locate and position the lid 404 onto and relative to the base 402. Fixture 400 differs from fixture 200 and fixture 300 in that the fixture 400 is not rectangular along the exterior surfaces. More specifically, the first contour 406 and the second contour 414 form bulging regions 424 that protrude outward from base plates 426. The rectangular shapes of fixture 200 and fixture 300 facilitate stacking of multiple fixtures that are the same in form as fixture 200 and 300 without the need for another external support. Fixture 400 on the other hand may require and additional fixture or support system to facilitate stacking of multiple fixtures having the form of fixture 400.

[0065] Referring to Figures 9 and 10, a fourth embodiment of a fixture 500 that is operable to receive the filament mesh structure 90 is illustrated. More specifically, the fixture 500 maybe operable to receive the cushion 50 after the filament mesh structure 90 has been further shaped or contoured with other manufacturing processes, such as molding of the entire blank (e.g., the filament mesh structure 90 before being formed into the cushion 50) or a portion thereof.

[0066] The fixture 500 may comprise a base 502. The base 502 may include contour 506. The contour 506 may comprise an indentation, recess, or cavity having a particular shape that is operable to receive and is complimentary to the first region 208 of the filament mesh structure 90. More specifically, the contour 506 may be operable to receive and may be complimentary to the profile 210 of the exterior surface 212 of the filament mesh structure 90 along either the first region 208 or the second region 216.

[0067] The contour 506 is operable to engage the first region 208 or the second region 216, or more specifically the profile 210 of the exterior surface 212 along the first region 208 or the second region 216 during an annealing process (e.g., a heat-treating process) to maintain a preformed shape of the first region 208 and / or exterior surface 212 of the filament mesh structure 90 along the first region 208 or the second region 216. More specifically the contour 506 may be operable to maintain a preformed shape of the first region 208 or the second region 216 and / or exterior surface 212 of the cushion 50 along the first region 208 or the second region 216 after the21866-US-lfilament mesh structure 90 has been further shaped or contoured with other manufacturing processes to form the cushion 50.

[0068] The fixture 500 comprises a plurality plates or slats 508 defining an array of orifices 509 to facilitate air flow to the filament mesh structure 90, or more specifically the cushion 50 after the filament mesh structure 90 has been further shaped or contoured, during the annealing process (e.g., a heat-treating process). The slats 508 may be arranged in first and second rows, columns, or arrays 510, 512. The first and second arrays 510, 512 may be orthogonal to each other. Side inserts or side plates 514 may protrude laterally outward from the slats 508. The side plates 514 may facilitate supporting the fixture 500 via an external object, particularly from below the fixture 500. The slats 508 may be perforated (e.g., may defined orifices 516) to facilitate air flow to the filament mesh structure 90, or more specifically the cushion 50, during the annealing process (e.g., a heat-treating process). The number of slats 508 may be increased to increase the contact between the fixture 500 and the filament mesh structure 90, or more specifically the cushion 50, to reduce an imprint from the fixture 500 onto the filament mesh structure 90, or more specifically the cushion 50. Alternatively, side facings (e.g., a material having a continuous surface) may be disposed along the contour 506 to prevent or eliminate the fixture from imprinting onto the filament mesh structure 90, or more specifically the cushion 50. The fixture 500 may be configured such that multiple fixtures having the form of fixture 500 may be stacked on top of each other.

[0069] Referring to Figure 11, a flowchart of a method 600 for processing the filament mesh structure 90 is illustrated. The method 600 begins at block 602, where the filament mesh structure 90, or more specifically the cushion 50, is formed. This may include molding the filament mesh member 90 to form the exterior profile 210 into a desire shape. Next, the method 600 moves onto block 604 where the filament mesh structure 90, or more specifically the cushion 50, is disposed within a fixture (e.g., fixture 200, fixture 300, figure 400, or fixture 500) such that a contour (e.g., first contour 206, second contour 214, first contour 306, second contour 314, first contour 406, second contour 414, contour 506, etc.) of the fixture engages the exterior profile 210 of the filament mesh structure 90, or more specifically the cushion 50.

[0070] The method 600 next moves on to block 606 where a first portion (e.g., lid 204, lid 304, or lid 404) of the fixture is located relative to the second portion (e.g., base 202, base 302, or21866-US-lbase 402) of the fixture. For example, the locators 326 of fixture 300 may engage the orifices 328 to properly locate lid 304 relative to base 302 prior to sliding the lid 304 into position on the base 302. Once the first portion of the fixture is located relative to the second portion of the fixture, the first portion of the fixture may be secured to the second portion of the fixture such that the portions of the contour along the first and second portions (e.g., first contour 206 and second contour 214, first contour 306 and second contour 314, first contour 406 and second contour 414, etc.) of the fixture engage the exterior profile the filament mesh structure 90, or more specifically the cushion 50. It is noted that step at block 606 may not be required, particularly if the fixture only includes one section (e.g., base 502 of fixture 500).

[0071] Next, the method 600 moves on to a block 608. At block 608, multiple fixtures (e.g., two or more) each having one filament mesh structure 90, or more specifically one cushion 50, disposed therein according to block 604 may be stacked on top of each other. For example, first and second filament mesh structures 90, or more specifically first and second cushions 50, may be disposed within first and second fixtures (e.g., fixture 200, fixture 300, figure 400, or fixture 500) such that a contours (e.g., first contour 206, second contour 214, first contour 306, second contour 314, first contour 406, second contour 414, contour 506, etc.) of the first and second fixtures engage the exterior profiles 210 of the first and second filament mesh structures 90, or more specifically the first and second cushions 50. The first and second fixtures may then be stacked (e.g., the second fixture may be stacked on top of the first fixture).

[0072] The method 600 then moves on to block 610 where the filament mesh structure 90, or more specifically the cushion 50, is annealed (e.g., heat-treated) within the fixture to alter a hardness or rigidity of the filament mesh structure 90, or more specifically the cushion 50, such that the contour (e.g., first contour 206, second contour 214, first contour 306, second contour 314, first contour 406, second contour 414, contour 506, etc.) of the fixture engages the exterior profile 210 of the filament mesh structure 90, or more specifically the cushion 50, during the annealing to prevent deformation of the filament mesh structure 90, or more specifically the cushion 50, and maintain a desired shape of the exterior profile 210. The hardness or rigidity of the filament mesh structure 90, or more specifically the cushion 50, may be altered during the annealing to reduce or eliminate variation in the hardness or rigidity and such that the hardness or rigidity becomes uniform throughout the filament mesh structure 90, or more specifically the cushion 50. It is noted21866-US-lthat several filament mesh structures 90, or more specifically cushions 50, may be annealed simultaneously in a stacked configuration within individual fixtures (e.g., see block 608). However, the annealing process may include only annealing one filament mesh structure 90, or more specifically one cushion 50, within a single fixture if the steps at block 608 are omitted. The annealing process may either increase or decrease the hardness or rigidity of the filament mesh structures 90, or more specifically the cushions 50.

[0073] During the annealing the filament mesh structures 90, or more specifically the cushions 50, may lose their molded shapes due to the heat treatment and previous shape memory of the material. The fixtures (e.g., fixture 200, fixture 300, figure 400, and fixture 500) are operable to engage the filament mesh structures 90, or more specifically the cushions 50, to maintain the desired shapes (e.g., exterior profiles 210) during annealing. It should be understood that the flowchart in Figure 11 is for illustrative purposes only and that the method 600 should not be construed as limited to the flowchart in Figure 11. Some of the steps of the method 600 may be rearranged while others may be omitted entirely.

[0074] Clause 1. A product comprising: an annealed mesh member, the mesh member comprising a set of filaments of polymeric material, wherein at least two members of the set of filaments are looped and bonded to each other, the annealed mesh member comprises an increased stiffness relative to the mesh member prior to annealing, and a contour along an exterior of the annealed mesh member is the same as the mesh member prior to annealing.

[0075] Clause 2. The product of clause 1, wherein a cross section of the annealed mesh member comprises a varying dimension such that the contour along the exterior of the annealed mesh member is non-planar and includes one or more curved regions.

[0076] Clause 3. The product of clauses 1 to 3, wherein the annealed mesh member comprises a vehicle seat back.

[0077] Clause 4. The product of clauses 1 to 3, wherein the annealed mesh member comprises a vehicle seat bottom.21866-US-l

[0078] Clause 5. The product of clauses 1 to 3, wherein the set of filaments of the polymeric material of the annealed mesh member comprises a crystalline structure comprising aligned molecules that increase the stiffness of the annealed mesh member.

[0079] Clause 6. A method comprising: disposing a filament mesh member within a fixture such that a contour of the fixture engages an exterior profile of the filament mesh member; and annealing the filament mesh member within the fixture such that the contour of the fixture engages the exterior profile of the filament mesh member during the annealing and maintains a desired shape of the exterior profile.

[0080] Clause 7. The method of clause 6 further comprising molding the filament mesh member.

[0081] Clause 8. The method of clauses 6 to 7, wherein the fixture comprises a first fixture and the filament mesh member comprises a first filament mesh member, and further comprising: disposing a second filament mesh member within a second fixture such that a contour of the second fixture engages an exterior profile of the second filament mesh member, and stacking a second fixture on top of the first fixture.

[0082] Clause 9. The method of clauses 6 to 8, wherein the annealing comprises annealing the first and second filament mesh members within the first and second fixtures, respectively, and while the second fixture is stacked on top of the first fixture.

[0083] Clause 10. The method of clauses 6 to 9, wherein the fixture includes first and second portions, each defining a portion of the contour, and further comprising: securing the first portion of the fixture to the second portion of the fixture prior to the annealing such that the portions of the contour along the first and second portions of the fixture engage the exterior profile of the filament mesh member.

[0084] Clause 11. The method of clause 10 further comprising locating the first portion of the fixture relative to the second portion prior to securing the first portion of the fixture to the second portion of the fixture.21866-US-l

[0085] Clause 12. A fixture comprising: a base comprising a contour that is operable to (i) receive and is complimentary to a profile of an exterior surface of a filament mesh member comprising a set of filaments of thermoplastic material and (ii) engage the exterior surface of the filament mesh member during an annealing process to maintain a preformed shape of the exterior surface of the filament mesh member.

[0086] Clause 13. The fixture of clause 12, wherein the fixture comprises a plurality of slats defining and array of orifices to facilitate air flow to the filament mesh member during the annealing process..

[0087] Clause 14. The fixture of clause 13, wherein the slats are arranged in first and second arrays, wherein the first and second arrays are orthogonal to each other.

[0088] Clause 15. The fixture of clauses 13 to 14 further comprising side plates protruding laterally outward from the slats, wherein the side plates facilitate supporting the fixture.

[0089] Clause 16. The fixture of clauses 13 to 15, wherein the slats are perforated to facilitate air flow to the filament mesh member during the annealing process.

[0090] Clause 17. The fixture of clauses 12 tol6 further comprising a lid removably disposable onto the base.|0091] Clause 18. The fixture of clause 17, wherein the base and lid of the fixture each define a portion of the contour.

[0092] Clause 19. The fixture of clauses 16 tol8 further comprising locators that are disposed on one of the base or the lid that are operable to engage the other of the base and the lid to locate and position the lid relative to the base.

[0093] Clause 20. The fixture of clause 16 to 19, wherein the base and lid each define orifices to facilitate air flow to the filament mesh member during the annealing process.

[0094] It should be understood that the designations of first, second, third, fourth, etc. for any component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Furthermore, it should be understood that21866-US-lany component, state, or condition described herein that does not have a numerical designation may be given a designation of first, second, third, fourth, etc. in the claims if one or more of the specific component, state, or condition are claimed.

[0095] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms according to the disclosure. In that regard, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, the features of various implementing embodiments may be combined to form further embodiments according to the disclosure.

Claims

21866-US-lWHAT IS CLAIMED IS:

1. A product comprising:an annealed mesh member, the annealed mesh member comprising a set of filaments of polymeric material, wherein at least two members of the set of filaments are looped and bonded to each other, the annealed mesh member comprises an increased stiffness relative to the mesh member prior to annealing, and a contour along an exterior of the annealed mesh member is the same as the mesh member prior to annealing.

2. The product of claim 1, wherein a cross section of the annealed mesh member comprises a varying dimension such that the contour along the exterior of the annealed mesh member is non-planar and includes one or more curved regions.

3. The product of claim 1, wherein the annealed mesh member comprises a vehicle seat back.

4. The product of claim 1, wherein the annealed mesh member comprises a vehicle seat bottom.

5. The product of claim 1, wherein the set of filaments of the polymeric material of the annealed mesh member comprises a crystalline structure comprising aligned molecules that increase the stiffness of the annealed mesh member.

6. A method comprising:disposing a filament mesh member within a fixture such that a contour of the fixture engages an exterior profile of the filament mesh member; andannealing the filament mesh member within the fixture such that the contour of the fixture engages the exterior profile of the filament mesh member during the annealing and maintains a desired shape of the exterior profile.

7. The method of claim 6 further comprising molding the filament mesh member.21866-US-l8. The method of claim 6, wherein the fixture comprises a first fixture and the filament mesh member comprises a first filament mesh member, and further comprising:disposing a second filament mesh member within a second fixture such that a contour of the second fixture engages an exterior profile of the second filament mesh member, and stacking a second fixture on top of the first fixture.

9. The method of claim 8, wherein the annealing comprises annealing the first and second filament mesh members within the first and second fixtures, respectively, and while the second fixture is stacked on top of the first fixture.

10. The method of claim 6, wherein the fixture includes first and second portions, each defining a portion of the contour, and further comprising:securing the first portion of the fixture to the second portion of the fixture prior to the annealing such that the portions of the contour along the first and second portions of the fixture engage the exterior profile of the filament mesh member.

11. The method of claim 10 further comprising locating the first portion of the fixture relative to the second portion prior to securing the first portion of the fixture to the second portion of the fixture.

12. A fixture comprising:a base comprising a contour that is operable to (i) receive and is complimentary to a profile of an exterior surface of a filament mesh member comprising a set of filaments of thermoplastic material and (ii) engage the exterior surface of the filament mesh member during an annealing process to maintain a preformed shape of the exterior surface of the filament mesh member.

13. The fixture of claim 12, wherein the fixture comprises a plurality of slats defining and array of orifices to facilitate air flow to the filament mesh member during the annealing process.21866-US-l14. The fixture of claim 13, wherein the slats are arranged in first and second arrays, wherein the first and second arrays are orthogonal to each other.

15. The fixture of claim 14 further comprising side plates protruding laterally outward from the slats, wherein the side plates facilitate supporting the fixture.

16. The fixture of claim 13, wherein the slats are perforated to facilitate air flow to the filament mesh member during the annealing process.

17. The fixture of claim 12 further comprising a lid removably disposable onto the base.

18. The fixture of claim 17, wherein the base and lid of the fixture each define a portion of the contour.

19. The fixture of claim 17 further comprising locators that are disposed on one of the base or the lid that are operable to engage the other of the base and the lid to locate and position the lid relative to the base.

20. The fixture of claim 17, wherein the base and lid each define orifices to facilitate air flow to the filament mesh member during the annealing process.

Images