Provided is a method for producing a foamed synthetic resin molded body. In this method, in the case where a hole-like portion is a through hole, when foam molding is performed, the occurrence of molding defects such as voids at the periphery of the hole-like portion can be sufficiently prevented or suppressed without forming a burr portion that closes the hole-like portion. Also in this method, in the case where the hole-like portion is a non-through hole, the occurrence of molding defects such as voids at a bottom portion of the hole-like portion can be sufficiently prevented or suppressed.

A layered cushion that may be fully disassembled for easy cleaning is disclosed herein. The sleep system is durable and fire retardant. The layered cushion may include a foam layer, a layer of void cells, and a cover. The foam permits fluids to move freely there through and contours to a user's body to maximize comfort and reduce interface pressure. The reticulated foam layer resists compression set and thermosetting. The layer of void cells also permits fluids to move freely there through and provide additional support to the user's body. The individual void cells of the void cell layer are perforated to allow the transmission of fluids there through. The cover couples the other layers together to form the layered cushion and prevents the layers from deteriorating. The cover is removable to permit cleaning each of the layers independently.

An apparatus and method for producing a vehicle interior component may include creating a plurality of molten polymeric filaments, and applying a fluid stream to the molten filaments to impart the desired shape while in a bath to cool them to form a consolidated filament structure. An assembly, system, and method are provided for shaping a plurality of strands of a molten thermoplastic resin as a contoured unitary mesh product via at least one shaping conveyor. Another assembly, system, and method are provided for shaping a plurality of strands of a molten thermoplastic resin as a contoured unitary mesh product via an actuator assembly having one or more actuators.

A method for producing a seat cushion includes a molten filament supplying step of discharging a plurality of molten filaments of a thermoplastic resin or the like downward in a thermal vertical direction from a plurality of nozzle holes, a three-dimensional filaments fused body forming step of fusion-bonding contact points between the plurality of molten filaments while three-dimensionally entangling the molten filaments to form a three-dimensional filaments fused body, and a three-dimensional filaments-linked structure forming step of cooling and solidifying the three-dimensional filaments fused body while drawing the three-dimensional filaments fused body with an underwater drawing machine provided in cooling water to thereby form a three-dimensional filaments-linked structure, the three-dimensional filaments-linked structure forming step includes a three-dimensional filaments-linked structure density controlling step of controlling a density of the three-dimensional filaments fused body by varying a drawing speed of the underwater drawing machine.

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

A product is provided with a body with a nonrectangular cross section with a mesh of strands of expanded thermoplastic resin. A density of the mesh of strands about a perimeter of the nonrectangular cross section is greater than within the perimeter. The perimeter is provided with at least one recess formed therein.

A seat cushion includes a mesh member embedded into a foam member. The mesh member comprises a set of filaments of polymeric material which are looped and bonded to each other. The mesh increases rigidity, cut resistance, tear resistance, and abrasion resistance of the foam member, eliminating the need for scrim and border wire in some applications.

A method of manufacturing a product, dispenses, through a tool with an aperture sized to match an overall perimeter of a product, a molten thermoplastic resin. The tool generates a plurality of strands through the tool aperture while maintaining the plurality of strands within the overall perimeter of the product. The strands are buckled by resisting a flow of the plurality of strands. The buckled strands intersect as a unitary non-woven body in a shape of the overall perimeter of the product.

A composite component includes an outer skin that is formed from a thermoplastic polyurethane (TPU) elastomer, within a thermoforming mold, into a desired shape, a mesh reinforcement layer formed from a blend of TPU and polyester fibers and attached to an inner surface of the outer skin, and a padding that is formed from a TPU foam and applied to the inner surface of the outer skin and comprising one of liquid TPU foam that is poured within the desired shape of the outer skin, a plurality of gas-filled TPU beads that are melted to one another at points of contact of outer surfaces of adjacent beads, or one of TPU foam that is molded to a desired shape, or TPU foam that is cut in the desired shape from a bulk piece of TPU foam.

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.