Mesh structure and method of manufacture

Patent metadata

Field	Value
Publication number	US-2026001293-A1
Application number	US-202318877717-A
Country	US
Kind code	A1
Filing date	Jun 21, 2023
Priority date	Jun 22, 2022
Publication date	Jan 1, 2026
Grant date	—

Abstract

A filament mesh structure, methods of manufacture and forming the filament mesh structure, and seat assembly having the filament mesh structure. The filament mesh structure may be cut by a fluid jet, may be heated with fluid to facilitate reshaping, or both. The filament mesh structure may be provided with a foldable connecting segment that facilitates folding of the filament mesh structure.

First claim

1 . A method of manufacture and forming a filament mesh structure, the method comprising:
cutting a filament mesh structure with a fluid jet.

2 . The method of claim 1 wherein cutting the filament mesh structure with the fluid jet at least partially forms a cushion.

3 . The method of claim 2 further comprising attaching the cushion to a frame of a seat assembly.

4 . The method of claim 3 further comprising positioning a trim cover over the cushion and attaching the trim cover to the cushion, to the frame, or to the cushion and the frame.

5 . The method of claim 1 further comprising forming the filament mesh structure with filaments of thermoplastic material, the filaments being randomly looped and bonded.

6 . The method of claim 5 wherein forming the filament mesh structure includes extruding the thermoplastic material through a die to form the filaments and then passing the filaments through a funnel.

7 . The method of claim 6 further comprising cutting the filament mesh structure after the filaments pass through the funnel.

8 . The method of claim 1 further comprising controlling a travel speed of a cutting head to control a depth of a cut into the filament mesh structure.

9 . The method of claim 8 further comprising decreasing the travel speed of the cutting head to increase the depth of the cut.

10 . The method of claim 8 further comprising moving the cutting head closer to the filament mesh structure to increase the depth of the cut.

11 . The method of claim 8 further comprising increasing a fluid pressure provided to the cutting head to increase the depth of the cut.

12 . The method of claim 8 further comprising increasing a fluid flow rate of the fluid jet to increase the depth of the cut.

13 . The method of claim 8 wherein cutting the filament mesh structure with the fluid jet includes positioning the cutting head remotely from the filament mesh structure such that the cutting head does not contact the filament mesh structure.

14 . The method of any claim 8 further comprising controlling an automation supporting the cutting head to move the cutting head along a cutting path relative to the filament mesh structure.

15 . The method of claim 14 further comprising controlling the automation in at least one degree of freedom to move the cutting head along the cutting path.

16 . The method of claim 14 further comprising controlling the automation in at least three degrees of freedom to move the cutting head along the cutting path.

17 . The method of claim 1 further comprising cutting entirely through the filament mesh structure via the fluid jet.

18 . The method of claim 1 further comprising cutting partially through the filament mesh structure via the fluid jet.

19 . The method of claim 1 further comprising cutting one or more of a planar surface and a curved contour in the filament mesh structure via the fluid jet.

20 . The method of claim 1 further comprising-further comprising cutting one or more of an orthogonal surface, a fillet, a chamfer, and a trench in the filament mesh structure via the fluid jet.

21 - 119 . (canceled)

120 . A cushion manufactured by the method of claim 1 .

121 - 125 . (canceled)

Assignees

• Lear Corp

Inventors

• Valenzuela Ibrahim
• Liu Haifeng
• Swikoski Lisa
• Geisler Kevin M
• Brudzynsky Michelle A
• Hudson Curtis
• Kandasamy Jaiviknesh
• Severinski Paul
• Johnson Christopher D
• Webster William
• Kazyak David
• Munroe Jeanene F
• Hallock Joshua
• Blair Samuel
• Abdella David

Classifications

• B29K2101/12

  Thermoplastic materials · CPC title

• B29D99/0092 Primary

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

• B60N2/7017 Primary

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

• D04H3/037

  reorientation by liquid · CPC title

• D04H3/16 Primary

  with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion · CPC title