Cushion, manufacturing apparatus, and a method of manufacture

Patent metadata

Field	Value
Publication number	US-2025121755-A1
Application number	US-202418790311-A
Country	US
Kind code	A1
Filing date	Jul 31, 2024
Priority date	Oct 17, 2023
Publication date	Apr 17, 2025
Grant date	—

Abstract

A cushion, a manufacturing apparatus, and a method of manufacture. The cushion comprises a mesh member that comprises a set of filaments. Each member of the set of filaments is looped and bonded to at least one other member of the set of filaments. The mesh member defines a first side that comprises a repeating non-planar profile.

First claim

1 . An apparatus comprising:
a funnel comprising a set of sides that cooperate to define an inlet opening and an outlet opening; and an actuator that is operatively connected to the funnel, wherein at least one member of the set of sides is vibratable by the actuator.

2 . The apparatus of claim 1 wherein the set of sides are fixedly positioned with respect to each other and the set of sides are vibratable by the actuator.

3 . The apparatus of claim 1 further comprising a sheet that is disposed on at least one member of the set of sides and that faces toward the inlet opening, wherein the sheet is vibratable with the at least one member of the set of sides.

4 . The apparatus of claim 1 wherein a first member of the set of sides is moveable with respect to a second member of the set of sides.

5 . The apparatus of claim 4 wherein an area of the inlet opening and an area of the outlet opening is variable.

6 . The apparatus of claim 4 further comprising a second actuator, wherein the first member of the set of sides is vibratable by the actuator and the second member of the set of sides is vibratable with the second actuator.

7 . The apparatus of claim 6 wherein the first and second members of the set of sides are disposed opposite each other, and the actuator and the second actuator is configured to move the first and second members of the set of sides, respectively, toward each other.

8 . A method comprising:
extruding a set of filaments into a funnel, the funnel comprising a set of sides and an outlet opening that is defined by the set of sides; and vibrating at least one member of the set of sides of the funnel against a subset of the set of filaments, thereby shaping the subset of the set of filaments with a non-planar profile.

9 . The method of claim 8 wherein vibrating changes an area of the outlet opening.

10 . The method of claim 8 wherein vibrating further comprises vibrating the set of sides without changing an area of the outlet opening.

11 . The method of claim 8 wherein extruding the set of filaments further comprises extruding the set of filaments through a die and vibrating further comprises vibrating at least one member of the set of sides toward and away from the die while extruding the set of filaments.

12 . The method of claim 8 further comprising dispensing a fluid onto at least one member of the set of sides while vibrating at least one member of the set of sides.

13 . The method of claim 8 further comprising dispensing a fluid onto a sheet that is disposed on at least one member of the set of sides while vibrating at least one member of the set of sides.

14 . The method of claim 8 further comprising dispensing a fluid through a sheet that is disposed on at least one member of the set of sides while vibrating at least one member of the set of sides.

15 . A cushion comprising:
a mesh member comprising a set of filaments of thermoplastic material, wherein each member of the set of filaments is looped and bonded to at least one other member of the set of filaments, the mesh member defining a first side that comprises a repeating non-planar profile.

16 . The cushion of claim 15 wherein the mesh member further comprises a second side and comprises a second repeating non-planar profile.

17 . The cushion of claim 15 wherein the mesh member further comprises a second side that is disposed opposite the first side and the second side does not comprise the repeating non-planar profile.

18 . The cushion of claim 15 wherein the repeating non-planar profile is a waveform.

19 . The cushion of claim 15 wherein the repeating non-planar profile is a periodic waveform.

20 . The cushion of claim 19 wherein the repeating non-planar profile is a sinusoidal waveform.

Assignees

• Lear Corp

Inventors

• Repke Eric

Classifications

• B29D99/0092

  Producing upholstery articles, e.g. cushions, seats (B29C63/025 takes precedence) · CPC title

• B60N2/62 Primary

  Thigh-rests {(B60N2/914 takes precedence)} · CPC title

• B60N2/7035

  Cushions · CPC title

• B60N2/7017 Primary

  characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for · CPC title