GB2635615A

GB2635615A - Method and apparatus for producing a cushion

Info

Publication number: GB2635615A
Application number: GB2417376.7A
Authority: GB
Inventors: Valenzuela Ibrahim; Liu Haifeng; Swikoski Lisa; M Geisler Kevin; A Brudzynsky Michelle; F Munroe Jeanene; A Himmel Joseph
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2022-05-11
Filing date: 2023-05-11
Publication date: 2025-05-21
Also published as: CN119562929A; KR20250003778A; EP4522553A1; EP4522553A4; JP2025515735A; WO2023220261A1; GB202417376D0

Abstract

Cushions, seat assemblies, apparatuses, and methods for producing the same are disclosed. The methods may include heating a polymeric material to a molten state, such that it becomes a molten polymer. The molten polymer may then be introduced to various embodiments of die plates such as a die plate having a first area and a different second area. For example, one area may have more open area having an open portion and a closed portion. In another embodiment, the die plate may include a slit for producing a film. A heating apparatus may heat the molten strands after exiting the die plate. In still another embodiment, the cushion may be made from a body of intertwined and/or entangled polymeric strands and bolsters attached thereto. In yet another embodiment, the die may be configured to provide a cushion having areas of different hardness.

Claims

WHAT IS CLAIMED IS:

1. A method for producing a vehicle interior component, comprising: heating a polymeric material to a molten state, such that it becomes a molten polymer; introducing the molten polymer into a die plate having a first area containing a plurality of first holes therethrough and a second area containing a plurality of second holes therethrough, the first holes together defining a first open space per unit area in the first area and the second holes together defining a second open space per unit area in the second area, and wherein the first open space per unit area is greater than the second open space per unit area; and cooling the molten polymer after it leaves the die plate.

2. The method of claim 1, wherein there are more of the first holes per unit area in the first area than the second holes per unit area in the second area.

3. The method of claims 1 or 2, wherein the first holes have a larger diameter than the second holes.

4. The method of any of the preceding claims, wherein cooling the polymer after it leaves the die plate produces a cushion blank, the method further comprising masking a portion of the die plate with a template having a predefined outline portion such that the cushion blank has a cross section that is defined by the predefined outline portion.

5. The method of claim 4, wherein the second area includes a location that corresponds to a location of an occupant sensor in the cushion blank.

6. The method of claims 4 or 5, wherein the die plate includes two of the first areas, each being positioned in a location that corresponds to a respective bolster area of the cushion blank.

7. The method of claim 6, wherein the die plate includes a third area containing a plurality of third holes therethrough, the third holes together defining a third open space per unit ar ea in the third area, and wherein the third open space per unit area is less than the second open space per unit area.

8. A vehicle interior component formed hy the method of any of the preceding claims.

9. A method for producing a vehicle interior component, comprising: heating a polymeric material to a molten state, such that it becomes a molten polymer; introducing the molten polymer into a die plate including a first area having an open portion and a closed portion and a second area having an open portion and a closed portion, and wherein a ratio of the open portion of the first area to the first area is greater than a ratio of the open portion of the second area to the second area; and cooling the molten polymer after it leaves the die plate.

10. The method of claim 9, wherein the first area includes a plurality of first holes defining the open portion of the first area, and the second area includes a plurality of second holes defining the open portion of the second area, and wherein there are more of the first holes per unit area in the first area than the second holes per unit area in the second area.

11. The method of claims 9 or 10, wherein the first area includes a plurality of first holes defining the open portion of the first area, and the second area includes a plurality of second holes defining the open portion of the second area, and wherein the first holes have a larger diameter than the second holes.

12. The method of any of claims 9-11, wherein the vehicle interior component includes a cushion blank having a cross section, the method further comprising masking a portion of the die plate with a template having an outline defining the cross section of the cushion blank.

13. The method of claim 12, wherein the die plate includes a plurality of the first areas, each being positioned in a location that corresponds to a respective bolster area of the cushion blank.

14. The method of claims 12 or 13, wherein the second area includes a location configured to receive an occupant sensor in the cushion blank.

15. The method of any of claims 9-14, wherein the die plate further includes a third area having an open portion and a closed portion, and wherein the ratio of the open portion of the second area to the second area is greater than a ratio of the open portion of the third area to the third area.

16. A die-plate arrangement usable to produce a vehicle interior component, comprising: a plate including a first area containing a plurality of first holes therethrough and a second area containing a plurality of second holes therethrough, the first holes together defining a first open portion in the first area and the second holes together defining a second open portion in the second area, and wherein a ratio of the first open portion to the first area is greater than a ratio of the second open portion to the second area.

17. The die-plate arrangement of claim 16, wherein there are more of the first holes per unit area in the first area than the second holes per unit area in the second area.

18. The die-plate arrangement of claims 16 or 17, wherein the first holes have a larger diameter than the second holes.

19. The die-plate arrangement of any of claims 16-18, further comprising a template configured to cover at least a portion of the first holes, at least a portion of the second holes, or at least a portion of the first holes and the second holes, the template having a predefined outline portion defining a cross section of a portion of the vehicle interior component.

20. The die-plate arrangement of any of claims 16-19, wherein the vehicle interior component is a seat cushion, and the plate includes two of the first areas, each being positioned in a location that corresponds to a respective bolster area of the seat cushion.

21. A method of manufacturing a product, comprising: dispensing, through a tool with an aperture sized to match an overall perimeter of a product, a molten thermoplastic resin, the tool generating a plurality of strands through the tool aperture while maintaining the plurality of strands within the overall perimeter of the product; and buckling the strands by resisting a flow of the plurality of strands, the buckled strands intersecting as a unitary non-woven body in a shape of the overall perimeter of the product.

22. The method of claim 21 further comprising cooling the plurality of strands as a unitary non-woven product.

23. The method of claim 21 further comprising: dispensing the molten thermoplastic resin from a plurality of nozzles, the plurality of nozzles, collectively, comprising an area greater than the area of the aperture; and closing a subset of the plurality of nozzles outside the area of the aperture.

24. The method of claim 21 further comprising providing a plate as the tool.

25. The method of claim 21 further comprising cooling the tool.

26. The method of claim 21 further comprising providing a mold with the aperture as the tool.

27. The method of claim 26 further comprising providing cooling passages through the mold to cool the unitary non-woven product.

28. The method of claim 27 further comprising placing the mold in a cooling fluid, the cooling fluid cooling the unitary non-woven product.

29. A product manufactured according to a method comprising: dispensing, through a tool with an aperture sized to match an overall perimeter of a product, a molten thermoplastic resin, the tool generating a plurality of strands through the tool aperture while maintaining the plurality of strands within the overall perimeter of the product; and buckling the strands by resisting a flow of the plurality of strands, the buckled strands intersecting as a unitary non-woven body in a shape of the overall perimeter of the product.

30. The product of claim 29 wherein the product further comprises a unitary nonwoven cushion.

31. The product of claim 29 wherein the product further comprises a concave contoured perimeter.

32. A tool comprising: a tool body with a through aperture, the through aperture sized to match an overall perimeter of a cushion, the through aperture configured to receive a molten thermoplastic resin as a plurality of dispensed strands; and the tool through aperture configured to maintain the plurality of dispensed strands within the overall perimeter of the cushion.

33. The tool of claim 32 wherein the through aperture is shaped as a seat cushion, the through aperture configured to form a unitary non-woven cushion.

34. The tool of claim 32 wherein the through aperture is shaped with curvature, the through aperture configured to form a unitary non-woven cushion with curvature.

35. The tool of claim 32 wherein the through aperture is provided with a plurality of curvatures of at least twelve millimeters radii.

36. The tool of claim 32 wherein the through aperture is formed with a convex perimeter to form a concave surface on the cushion.

37. A system to manufacture a cushion, comprising: a dispenser of molten thermoplastic resin; and the tool of claim 32 oriented relative to the dispenser to receive the molten thermoplastic resin.

38. The system of claim 37 further comprising a fluid chamber to receive the molten thermoplastic resin to resist a flow of the plurality of dispensed strands to buckle the strands to intersect as a unitary non-woven body in a shape of the overall perimeter of the cushion.

39. The system of claim 38 wherein the tool is oriented within the fluid chamber to cool the plurality of dispensed strands as a unitary non-woven cushion.

40. The system of claim 39 wherein cooling passages are formed through the tool to cool the plurality of dispensed strands as the unitary non-woven cushion.

41. A method comprising: dispensing a molten thermoplastic resin as a plurality of strands and at least one film; and resisting a flow of the dispensed plurality of strands, the resisting expanding the plurality of strands by intersecting and bonding at least a subset of the plurality of strands with each other and the at least one film as a unitary body.

42. The method of claim 41 , further comprising cooling the plurality of strands and the at least one film as a unitary product.

43. The method of claim 42, further comprising: cooling the plurality of strands and the at least one film with a fluid, wherein the flow of the plurality of strands is resisted by the fluid.

44. The method of claim 43, further comprising cooling the plurality of strands in a fluid chamber.

45. The method of any of the preceding claims, further comprising dispensing the at least one film on an exterior surface of the unitary body.

46. The method of any of the preceding claims, further comprising dispensing the at least one film between at least two subsets of the plurality of strands.

47. The method of any of the preceding claims, further comprising forming an aperture through the at least one film.

48. The method of any of the preceding claims, wherein dispensing further comprises: dispensing the plurality of strands through a plurality of apertures in a tool; and dispensing the at least one film through at least one slit in the tool.

49. The method of claim 48, further comprising: removing the tool from an extruder; installing a second tool to the extruder; dispensing the molten thermoplastic resin as a second plurality of strands and a second film through the second tool; and resisting a flow of the dispensed second plurality of strands, the resisting expanding the second plurality of strands by intersecting at least a subset of the second plurality of strands with each other and the second film as a second unitary body that is different from the first unitary body.

50. The method of any of the preceding claims, further comprising assembling a seat with a cushion formed by the method.

51. A product formed by the method of any of the preceding claims.

52. A product formed by a method comprising: dispensing a molten thermoplastic resin as a plurality of strands and at least one film; and resisting a flow of the dispensed plurality of strands, the resisting expanding the plurality of strands by intersecting at least a subset of the plurality of strands with each other and the at least one film as a unitary body.

53. The product formed by the method of claim 52, further comprising: forming the at least one film on an exterior surface of the unitary body.

54. The product formed by the method of claims 52 or 53, further comprising: forming the at least one film as an impermeable film between at least two subsets of the plurality of strands.

55. The product formed by the method of any of claims 52-54, further comprising: forming an aperture through the at least one film.

56. A seat assembly manufactured by a method comprising: assembling a seat with a cushion formed by the method of any of claims 52-55.

57. The seat assembly manufactured by the method of claim 56, further comprising: attaching at least one of a seat trim, an actuator, and/or a heat transfer layer to the at least one film.

58. A product comprising : an expanded mesh of a plurality of interconnected thermoplastic strands; and at least one thermoplastic film integrally bonded to at least one subset of the plurality of strands as a unitary body.

59. The product of claim 58, wherein the at least one film is oriented on an exterior surface of the unitary body.

60. The product of claims 58 or 59, wherein the at least one film is impermeable.

61. The product of any of claims 58-60, wherein the at least one film is oriented between at least two subsets of the plurality of strands.

62. The product of any of claims 58-61, wherein an aperture extends through the at least one film.

63. A seat assembly comprising the product of any of claims 58-62, as a seat cushion.

64. The seat assembly of claim 63 further comprising at least one of a seat trim, an actuator, and/or a heat transfer layer attached to the at least one film.

65. A tool comprising a body with a plurality of apertures formed through the body and at least one slit formed through the body to dispense a molten thermoplastic resin through the plurality of apertures and the at least one slit.

66. A system comprising: an extruder of molten thermoplastic resin; and the tool of claim 65 mounted to the extruder to dispense the molten thermoplastic resin through the tool as a plurality of strands and at least one film.

67. A method for producing a vehicle interior component, comprising: heating a polymeric material to a molten state, such that it becomes a molten polymer; introducing the molten polymer into a die plate having a plurality of holes disposed therethrough such that the molten polymer moves through the holes and forms a plurality of molten polymeric filaments; surrounding the molten polymeric filaments with a heating arrangement operable to apply heat to the molten polymeric filaments; and introducing the molten polymeric filaments into a bath to cool the molten polymeric filaments to form a consolidated filament structure.

68. The method of claim 67, wherein the heating arrangement comprises a rectangular heating structure to surround the molten polymeric filaments as the molten polymeric filaments leave the die plate.

69. The method of claim 67 or 68, wherein the die plate includes a plurality of sides, and the heating arrangement is attached to each of the sides of the die plate.

70. The method of any of the previous claims, wherein the heating arrangement is configured to control an ambient temperature around the molten polymeric filaments to a temperature of 60C-140C.

71. The method of any of the previous claims, wherein the heating arrangement is positioned at least 100 mm-150 mm from the molten polymeric filaments.

72. The method of any of the previous claims, wherein the molten polymeric filaments include an outer portion disposed toward an outside edge of the die plate, and an inner portion disposed inward from the outer portion, and the heating arrangement is configured to heat the outer portion such that bonding between the molten polymeric filaments of the outer portion is greater than bonding between the molten polymeric filaments of the inner portion.

73. The method of any of the previous claims, wherein the molten polymer is a first molten polymer comprising a first material and the molten polymeric filaments are first molten polymeric filaments, and the method further comprises introducing a second molten polymer comprising a second material into the die plate such that the second molten polymer moves through the holes in the die plate and forms a plurality of second molten polymeric filaments.

74. The method of claim 73, wherein the first molten polymer is introduced into the die plate toward an outside edge of the die plate, and the second molten polymer is introduced into the die plate inward from the first molten polymer such that the first molten polymeric filaments at least partially surround the second molten polymeric filaments.

75. A vehicle interior component formed by the method of any of the previous claims.

76. A method for producing a vehicle interior component, comprising: heating a first polymeric material to a molten state to create a first molten polymer; extruding the first molten polymer to form a plurality of first molten polymeric filaments; heating an entire perimeter of the first molten polymeric filaments; and cooling the first molten polymeric filaments in a fluid bath to create a consolidated filament structure.

77. The method of claim 76, wherein the first molten polymer comprises a first material, and the method further comprises extruding a second molten polymer comprising a second material to form a plurality of second molten polymeric filaments.

78. The method of claim 77, wherein the first molten polymer and second molten polymer are extruded such that the first molten polymeric filaments at least partially surround the second molten polymeric filaments.

79. The method of any of claims 76-78, wherein heating the entire perimeter of the first molten polymeric filaments comprises heating the first molten polymeric filaments on four sides of the first molten polymeric filaments.

80. The method of any of claims 76-79, wherein heating the entire perimeter of the first molten polymeric filaments comprises heating the first molten polymeric filaments to a temperature of 60C-140C.

81. The method of any of claims 76-80, wherein the entire perimeter of the first molten polymeric filaments is heated such that bonding between the first molten polymeric filaments is greater than bonding between the second molten polymeric filaments.

82. A vehicle interior component formed by the method of any of claims 76-81.

83. A method for producing a vehicle interior component, comprising: heating a polymeric material to create a molten polymer; forming a plurality of molten polymeric filaments from the molten polymer by extruding the molten polymer through a die plate; heating an entire perimeter of the molten polymeric filaments with a heating arrangement; and cooling the molten polymeric filaments in a fluid bath to form a consolidated filament structure.

84. The method of claim 83, wherein the heating arrangement is attached to the die plate.

85. The method of claim 83 or 84, wherein the molten polymer is a first molten polymer comprising a first material and the molten polymeric filaments are first molten polymeric filaments, and the method further comprises introducing a second molten polymer comprising a second material into the die plate such that the second molten polymer moves through the die plate and forms a plurality of second molten polymeric filaments.

86. The method of claim 85, wherein the first molten polymer is introduced into the die plate toward an outside edge of the die plate, and the second molten polymer is introduced into the die plate inward from the first molten polymer such that the first molten polymeric filaments at least partially surround the second molten polymeric filaments.

87. A vehicle seat cushion component comprising: a plastic mesh base, the plastic mesh base comprising a first plurality of three- dimensional filament loops, the first plurality of three-dimensional filament loops composed of a first thermoplastic polymer, the plastic mesh base having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; a first bolster attached to the plastic mesh base at the first edge, the first foamed bolster comprising a second plurality of three-dimensional filament loops, the second plurality of three-dimensional filament loops composed of a second thermoplastic polymer different from the first thermoplastic polymer; and a second bolster attached to the plastic mesh base at the second edge.

88. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three- dimensional filament loops composed of the second thermoplastic polymer.

89. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three- dimensional filament loops composed of a third thermoplastic polymer different from the first thermoplastic polymer.

90. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three- dimensional filament loops composed of a third thermoplastic polymer different from the first and second thermoplastic polymers.

91. The vehicle seat cushion component of claim 87 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three- dimensional filament loops composed of a third thermoplastic polymer different from the first thermoplastic polymer.

92. The vehicle seat cushion component of claim 87 to 91 further comprising a third bolster comprises a fourth plurality of three-dimensional filament loops, the fourth plurality of three-dimensional filament loops composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

93. The vehicle seat cushion component of claims 87 to 92 wherein the plurality of three-dimensional filament loops includes a plurality of fused connection in which two loops are attached to each other.

94. The vehicle seat cushion component of any of claims 87 to 93, wherein at least a subset of loops in the plurality of three-dimensional filament loops are not parallel or aligned with each other.

95. The vehicle seat cushion component of any of claims 87 to 94, wherein loops in the plurality of three-dimensional filament loops are randomly oriented.

96. The vehicle seat cushion component of any of claims 87 to 95, wherein the thermoplastic polymer is an extruded thermoplastic polymer.

97. The vehicle seat cushion component of any of claims 87 to 96, wherein the thermoplastic polymer includes a component selected from the group consisting of polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane- based thermoplastic elastomer, and polyamide-based thermoplastic elastomer.

98. The vehicle seat cushion component of any of claims 87 to 97, wherein the thermoplastic polymer includes a first linear low-density polyethylene.

99. The vehicle seat cushion component of any of claims 87 to 97, wherein the thermoplastic polymer includes a second linear low-density polyethylene different than the first linear' low-density polyethylene.

100. A seat assembly comprising: a frame; and the cushion according to any one of claims 87-99, the cushion supported by the frame.

101. A tool comprising: a die defining a series of apertures arranged to extrude material for the stranded mesh material member for the cushion according to any one of claims 87-99, the series of apertures arranged to define the outer perimeter of the member to define the plastic mesh base, the first bolster and the second bolster.

102. The tool of claim 101 wherein the series of apertures are further arranged such that the outer perimeter defines the bolsters.

103. A method comprising: extruding a first thermoplastic polymer to form a plastic mesh base comprising a first plurality of three-dimensional filament loops, the plastic mesh base having a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face; and extruding a second thermoplastic polymer to form a first bolster attached to the plastic mesh base at the first edge, the first foamed bolster comprising a second plurality of three- dimensional filament loops, the second thermoplastic polymer different from the first thermoplastic polymer; and extruding material to form a second bolster attached to the plastic mesh base at the second edge.

104. The method of claim 103 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops composed of the second thermoplastic polymer.

105. The method of claim 103 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops composed of a third thermoplastic polymer different from the first thermoplastic polymer.

106. The method of claim 103 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops composed of a third thermoplastic polymer different from the first and second thermoplastic polymers.

107. The method of claim 103 wherein the second bolster comprises a third plurality of three-dimensional filament loops, the third plurality of three-dimensional filament loops composed of a third thermoplastic polymer different from the first thermoplastic polymer.

108. The method of claim 103 to 107 further comprising a third bolster comprises a fourth plurality of three-dimensional filament loops, the fourth plurality of three-dimensional filament loops composed of a fourth thermoplastic polymer different from the first thermoplastic polymer.

109. A foamless seat cushion comprising: a plurality of intertwined polymeric strands having a first group of intertwined polymeric strands with a first hardness, and a second group of intertwined polymeric strands having a second hardness that is different than the first hardness, wherein the first and second groups of intertwined polymeric strands are connected.

110. The foamless seat cushion of claim 109, wherein the first group of intertwined polymeric strands has a first average diameter, and the second group of intertwined polymer strands has a second average diameter that is different than the first average diameter.

111. The foamless seat cushion of any of the preceding claims, wherein the first group of intertwined polymeric strands defines a first bulk density, and the second group of intertwined polymeric strands has a second bulk density that is different than the first density.

112. The foamless seat cushion of any of the preceding claims, wherein the first hardness is less than the second hardness and the first hardness is no more than 5 kPa.

113. The foamless seat cushion of any of the preceding claims, wherein the second hardness is at least 5 kPa.

114. The foamless seat cushion of any of the preceding claims, further comprising a third group of intertwined polymeric strands from the plurality of intertwined polymeric strands having a third hardness, the second group of intertwined polymeric strands being disposed between the first and third groups of intertwined polymeric strands such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

115. The foamless seat cushion of any of the preceding claims, wherein the plurality of intertwined polymeric strands from a hardness gradient from a first region of the cushion to a second region of the cushion.

116. A vehicle seat assembly comprising a seat frame supporting the foamless cushion of any of the preceding claims.

117. A breaker plate comprising: a solid body defining a plurality of orifices, the plurality of orifices having a first group of orifices and a second group of orifices, the first group of orifices being present at a first orifice density and having a first average diameter, the second group of orifices being present at a second orifice density and having a second average diameter wherein the first orifice density different than the second orifice density and/or the first average diameter is different than the second average diameter.

118. The breaker plate of claim 117, wherein the first orifice density is different than the second orifice density.

119. The breaker plate of claim 117 or 118, wherein the first average diameter is different than the second average diameter.

120. The breaker plate of claim 117, 118, or 119, wherein the first orifice density is no more than 11.5 orifices per square inch.

121. The breaker plate of any of the claims 117-120, wherein the first and second average diameters are different by at least 0.4.

122. The breaker plate of any of the claims 117-121, wherein the first and second orifice density is different by at least 3.0 kg/m3.

123. A system for dispensing a polymeric resin comprising an extruder with the breaker plate of any of claims 117-122 disposed therein such that during operation the extruder extrudes strands of the polymeric resin through the plurality of orifices during operation.

124. A method of making a seat pad comprising: dispensing a molten polymeric resin through a die defining a plurality of orifices to dispense a plurality of polymeric strands into a medium interface defined by a first medium and a second medium such that at least a portion of polymeric strands are deflected, intertwines, and harden to form a non-foam cushion in the second medium; removing the non-foam cushion from the second medium; and drying the non-foam cushion, wherein the plurality of orifices includes (i) a first group of orifices arranged at a first density and defining a first average diameter and (ii) a second group of orifices arranged at a second density and defining a second average diameter, the first density being different than the second density and/or the first average diameter being different than the second average diameter such the non-foam cushion has a first region with a first hardness and a second region with a second hardness that is different than the first hardness.

125. The method of claim 124, wherein the plurality of orifices is defined by an interchangeable breaker plate.

126. The method of claim 124 or 125, wherein the plurality of orifices is arranged to form a size and/or distribution gradient such that the non-foam cushion has a gradient hardness.

127. The method of claim 124, 125, or 126, wherein the plurality of orifices includes a third group of orifices such that the non-foam cushion has a third region having a third hardness that is greater than the second hardness which is greater than the first hardness, the second region being disposed between the first and third regions.

128. The method of any of the preceding claims 124-127, wherein the plurality of orifices includes a third group of orifices such that the non-foam cushion has a third region having a third hardness that is different than the second hardness and within 10% of the first hardness, the second region being disposed between the first and third regions.

129. A cushion comprising: a mesh body comprising a plurality of interconnected polymeric filaments, wherein (i) the plurality of interconnected polymeric filaments comprises a first subset of polymeric filaments and a second subset of polymeric filaments that is different than the first subset of polymeric filaments; and/or (ii) at least a portion of the interconnected polymeric filaments is bonded to a polymeric film.

130. The cushion of any of claims 129 or 131-188, wherein the first and second subsets are interconnected.

131. The cushion of any of claims 129-130 or 132-188, wherein (a) the first subset has a first hardness and the second subset has a second hardness that is different than the first hardness, (b) the first subset has a first density and the second subset has a second density different than the first density, (c) the first subset has a first filament size and the second subset has a second filament size, and/or (d) the first subset is formed from a first polymeric material and the second subset is formed from a second polymeric material that is different than the first polymeric material.

132. The cushion of any of claims 129-131 or 133-188, wherein the first size is a first average diameter, and the second size is a second average diameter.

133. The cushion of any of claims 129-132 or 134-188, wherein the mesh body has a contoured profile.

134. The cushion of any of claims 129-133 or 135-188, wherein the hardness is a bulk hardness.

135. The cushion of any of claims 129-134 or 136-188, wherein the cushion is foamless.

136. The cushion of any of claims 129-135 or 137-188, wherein the portion of the interconnected polymeric filaments is integrally bonded to a polymeric film.

137. The cushion of any of claims 129-136 or 138-188, wherein the interconnected polymeric filaments and the polymeric film are made of the same polymeric material.

138. The cushion of any of claims 129-137 or 139-188, wherein the film forms a skin along the mesh body.

139. The cushion of any of claims 129-138 or 140-188, wherein the mesh body is non-woven.

140. The cushion of any of claims 129-139 or 141-188, wherein the mesh body includes a base portion and an additional bolster portion.

141. The cushion of any of claims 129-140 or 142-188, wherein the first subset forms the base portion, and the second subset forms the additional bolster portion.

142. The cushion of claim 140 or claim 141, wherein the base portion defines a first profile, and an additional portion defines a second profile that is different than the first profile.

143. The cushion of any of claims 140-142, wherein the additional bolster portion includes a first bolster.

144. The cushion of claim 143, wherein the first bolster is attached the base portion at a first edge of the base portion.

145. The cushion of any of claims 143-144, wherein the first bolster comprises the second subset of polymeric filaments.

146. The cushion of claim 145, wherein the first subset of polymeric filaments comprises a first polymeric material and the second subset of polymeric filaments comprises a second polymeric material that is different than the first polymeric material.

147. The cushion of any of claims 143-146, wherein the additional bolster portion comprises a second bolster.

148. The cushion of claim 147, wherein the second bolster is attached to the base portion at a second edge of the base portion.

149. The cushion of any of claims claim 147-148, wherein the second bolster is opposite the first bolster.

150. The cushion of any of claims 146, wherein the second bolster comprises a third subset of polymeric filaments of the plurality of interconnected polymeric filaments and the third subset of polymeric filaments is different than the first and/or second subset of polymeric filaments.

151. The cushion of claim 150, wherein the third subset of polymeric filament comprises a third polymeric material that is different than the first polymeric material and/or second polymeric material.

152. The cushion of any of claims 147-151, wherein the additional bolster portion comprises a third bolster.

153. The cushion of claim 152, wherein the third bolster is attached to the base portion at a third edge of the base portion.

154. The cushion of claim 153, wherein the third edge is a rear edge of the base portion.

155. The cushion of any of claim 152-154, wherein the third bolster comprises a fourth subset of polymeric filaments that is different than the first, second, and/or third subset of polymeric filaments.

156. The cushion of claim 155, wherein the fourth subset of polymeric filaments comprises a fourth polymeric material that is different than the first, second, and/or third polymeric material.

157. The cushion of any of claims 152-156, wherein the additional bolster portion comprises a fourth bolster.

158. The cushion of claim 157, wherein the fourth bolster is attached to the base portion at a fourth edge.

159. The cushion of any of claims 157-155, wherein the fourth bolster is opposite the third bolster.

160. The cushion of any of claims 158-159, wherein the fourth edge is a front edge of the base portion.

161. The cushion of any of claims 157-160, wherein the fourth bolster comprises a fifth subset of polymeric filaments that is different than the first, second, third, and/or fourth subset of polymeric filaments.

162. The cushion of claim 161, wherein the fifth subset of polymeric filaments comprises a fifth polymeric material that is different than the first, second, third, and/or fourth polymeric material.

163. The cushion of any of claims 129-162 or 164-188, wherein the plurality of interconnected polymeric filaments includes a thermoplastic polymer.

164. The cushion of any of claims 131-163 or 165-188, wherein the density is a bulk density.

165. The cushion of any of claims 129-164 or 166-188, wherein the first hardness is no more than 5 kPa.

166. The cushion of any of claims 129-165 or 167-188, wherein the first hardness is less than the second hardness.

167. The cushion of any of claims 129-166 or 168-188, wherein the second hardness is at least 5 kPa.

168. The cushion of any of claims 129-167 or 169-188, wherein the plurality of interconnected polymeric filaments comprises a third subset of polymeric filaments that is different than the first subset of polymeric filaments and different than the second subset of polymeric filaments.

169. The cushion of claim 168, wherein the third subset has a hardness that is different than the first and second subsets.

170. The cushion of any of claims 168-169, wherein the second subset is disposed between the first and third subsets.

171. The cushion of any of claims 168-170, wherein the first subset has a first hardness and the second subset has a second hardness such that the first hardness is less than the second hardness and the third hardness is greater than the second hardness.

172. The cushion of any of claims 129-171 or 173-188, wherein the plurality of interconnected polymeric filament has a hardness gradient from a first region to a second region.

173. The cushion of any of claims 129-172 or 174-188, wherein the polymeric film is arranged such that it forms an exterior surface of the mesh body.

174. The cushion of any of claims 129-173 or 175-188, wherein the polymeric film is impermeable.

175. The cushion of any of claims 129-174 or 176-188, wherein the polymeric film is arranged between a first subset of polymeric filaments and a second subset of polymeric filaments.

176. The cushion of any of claims 129-175 or 176-188, wherein the polymeric film defines an aperture.

177. The cushion of any of claims 129-176 or 178-188, wherein the plurality of interconnected polymeric filaments comprises a plurality of fused connections in which at least two filaments are bonded to each other.

178. The cushion of any of claims 129-177 or 179-188, wherein at least a portion of the polymeric filaments are not parallel or aligned.

179. The cushion of any of claims 129-178 or 180-188, wherein polymeric filaments in the plurality of interconnected polymeric filaments are randomly oriented.

180. The cushion of any of claims 129-179 or 181-188, wherein the plurality of interconnected polymeric filaments comprises a polymer selected from the group consisting of a polyolefin, a polyethylene, a polystyrene, a polyester, a polyurethane, and a polyamide.

181. The cushion of claim 180, wherein the polyethylene is a low-density polyethylene.

182. The cushion of any of claims 180-181, wherein the polyethylene is linear.

183. The cushion of any of claims 180-182, wherein the plurality of interconnected polymeric filaments includes an additional polyethylene that is different than a first polyethylene.

184. The cushion of any of claims 129-183, wherein the cushion is a seat cushion.

185. A seat assembly comprising a frame supporting the cushion of any of the claims 129-184.

186. The seat assembly of claim 185, wherein the seat assembly is a vehicular seat assembly.

187. The seat assembly of any of claims 185-186, further comprising a seat trim, an actuator, and/or a heat transfer layer attached to the polymeric film.

188. A vehicle comprising a floorboard and the seat assembly of any of claims 185-187 mounted to the floorboard.

189. A die tool comprising: a body defining a first section defining a first plurality of orifices such that it defines a first open space and a first closed portion and a second section defining one or more orifices such that it defines a second open space and a second closed portion wherein (i) the first open space and the first closed portion is different than the second open space and the second closed portion, (ii) the orifices define a shape of a final product having a first profile and a second profile that is different than the first profile, (iii) the one or more orifices includes an elongated orifices to define a polymeric film, and/or (iv) the first plurality of orifices is different than the one or more orifices.

190. The die tool of any of claims 189 or 191-220, wherein the first section has a different orifice density than the second section.

191. The die tool of any of claims 189 or 192-220, wherein the first plurality of orifices is a different size than the one or more orifices.

192. The die tool of any of claims 189-191 or 193-220, wherein the first plurality of orifices of the first section has a different average diameter than the one or more orifices of the second section.

193. The die tool of any of claims 189-192 or 194-220, wherein the one or more orifices forms at least one slit through the body.

194. The die tool of any of claims 189-193 or 195-220, wherein the orifices of the die tool are arranged to dispense molten thermoplastic resin.

195. The die tool of any of claims 189-194 or 196-220, wherein the one or more orifices are arranged to define the outer perimeter of a cushion having a first and second bolster.

196. The die tool of any of claims 189-195 or 197-220, wherein the one or more orifices is a second plurality of orifices.

197. The die tool of any of claims 189-196 or 198-220, wherein the first section defines a first area, the first open space defines a first open area, the second section defines a second area, and the second open space defines a second open area wherein the first open area to the first area defines a ratio that is greater than the second open area to the second area.

198. The die tool of any of claims 189-197 or 199-220, wherein the one or more orifices includes a through aperture sized to match an overall perimeter of a cushion.

199. The die tool of claim 198, wherein the through aperture is configured to receive a molten thermoplastic resin and dispense it as a plurality of molten filaments.

200. The die tool of claim 198 or claim 199, wherein the through aperture is configured to maintain the plurality of molten filaments.

201. The die tool of claim 190, wherein the first orifice density is no more than 8 orifice per square inch.

202. The die tool of claim 189 or claim 201, wherein the second orifice density is at least 9 orifice per square inch.

203. The die tool of claim 192, wherein the first and second average diameters are different by at least 0.4 mm.

204. The die tool of any of claims 189-203 or 205-220, wherein there are more orifices in the first section per unit area than orifices in the second section per unit area.

205. The die tool of any of claims 189-204 or 206-220, further comprising a template configured to cover at least a portion of the plurality of orifices and/or one or more orifices.

206. The die tool of claim 205, wherein the template has a predefined outline portion defining a cross section of a portion of a vehicle interior component.

207. The die tool of claim 205 or claim 206, wherein the template has a predefined outline portion defining a cross section of a portion of a cushion.

208. The die tool of claim 207, wherein the first section is positioned in a location that corresponds to respective bolster portions of the seat cushion.

209. The die tool of any of claims 198-200, wherein the through aperture is shaped as a seat cushion.

210. The die tool of any of claims 198-200 or 209, wherein the through aperture is configured to form a unitary non-woven cushion.

211. The die tool of any of claims 198-200 or 209-210, wherein tire through aperture is shaped with curvature to form a unitary non-woven cushion with curvature.

212. The die tool of any of claims 198-200 or 209-211, wherein the through aperture is provided with a plurality of curvatures of at least 12 mm radii.

213. The die tool of any of claims 198-200 or 209-212, wherein the through aperture is formed with a convex perimeter to form a concave surface of a cushion.

214. A dispensing system comprising a dispenser with the die tool of any of claims 189-213 or 215-220 disposed thereon such that during operation the dispenser dispenses a molten thermoplastic resin through the orifices of the die tool.

215. The dispensing system of claim 214, wherein the dispenser is an extruder to extrude the molten thermoplastic resin through the orifices of the die tool to form molten thermoplastic filaments.

216. The dispensing system of any of claims 214-215, further comprising a fluid chamber to receive the molten thermoplastic filaments to resist a flow of the molten thermoplastic filaments to buckle the filaments to intersect as a unitary non-woven body in a shape of the overall perimeter of the cushion.

217. The dispensing system of any of claims 214-216, wherein the die tool is aligned with the fluid chamber to cool the molten thermoplastic filaments as a unitary non-woven cushion.

218. The dispensing system of any of claim 214-217, wherein the die tool defines cooling passage formed through the die tool to cool the molten thermoplastic filaments as a unitary non-woven cushion.

219. A vehicle interior component comprising a plurality of interconnected polymeric filaments dispensed through the die tool of any of claims 189-218.

220. A cushion comprising a plurality of interconnected polymeric filaments dispensed through the die tool of any of claims 189-219.

221. A method comprising: dispensing a molten polymeric resin through a die assembly having a first region defining a first plurality of apertures to dispense molten polymeric filaments and a second region defining one or more additional apertures to dispense additional molten polymeric member that is different than the molten polymeric filaments, wherein the first region defines a first ratio of a first blocked area to a first open area that is different than a second ratio of a second blocked area to a second open area of the second region; and cooling the molten polymeric filaments and the additional molten polymeric member to form a mesh body including interconnected polymeric filaments and having a first portion different from a second portion.

222. The method of any of claims 221 or 223-297, wherein the mesh body is a nonfoam cushion.

223. The method of any of claims 221-222 or 224-297, wherein the mesh body is an interior vehicle component.

224. The method of any of claims 221-223 or 225-297, wherein the additional molten polymeric member is additional polymeric filaments having a different shape, size, density, and/or composition.

225. The method of any of claims 221-224 or 226-297, wherein the molten polymeric material is extruded through the die assembly.

226. The method of any of claim 221-224 or 227-297, wherein the first plurality of apertures or one or more additional apertures defines a perimeter in the shape of a final product.

227. The method of claim 226, wherein the final product is a seat cushion.

228. The method of any of claim 226 or claim 227, wherein the final product is an interior vehicle component.

229. The method of claims 221-228 or 230-297, wherein the first plurality of apertures defines a first profile that is different than a second profile defined by the one or more additional apertures.

230. The method of any of claims 221-229 or 231-297, wherein additional molten polymeric member is a polymeric film.

231. The method of claim 230, wherein the polymeric film is connected to the interconnected polymeric filaments.

232. The method of claim 230 or 231, wherein the polymeric film is bonded to the interconnected polymeric filaments.

233. The method of any of claims 221-232 or 234-297, wherein the molten polymeric filaments are dispensed into a medium interface defined by a first medium and a second medium such that at least a subset of the molten polymeric filaments is deflected and/or buckled such that it intersects, intertwines, and/or bonds while hardening to form the mesh body in the second medium.

234. The method of claim 233, further comprising removing the mesh body from the second medium and drying the mesh body.

235. The method of claim 233 or claim 234, wherein the first medium is a gas and the second medium is a liquid.

236. The method of any of claims 233-235, wherein the first medium is air, and the second medium is water.

237. The method of any of claims 221-236 or 238-297, wherein the plurality of apertures is arranged at a first aperture density and the one or more additional apertures is arranged at a second aperture density that is different than the first aperture density.

238. The method of any of claims 221-237 or 239-297, wherein the plurality of apertures defines a first average diameter, and the one or more additional apertures defines a second average diameter that is different than the first average diameter.

239. The method of any of claims 221-238 or 240-297, wherein the first portion of the mesh body has a first hardness and the second portion of the mesh body has a second hardness that is different than the first hardness.

240. The method of any of claims 221 -239 or 241-297, wherein a first thermoplastic polymer is dispensed through the orifice of the first region such that the first portion is a plastic mesh base of interconnected polymeric filaments and a second thermoplastic polymer is dispensed through the one or more orifice of die second region such that the second portion is a first plastic mesh bolster of interconnected polymeric filaments atached to the plastic mesh base, the second thermoplastic polymer being different than the first thermoplastic polymer.

241. The method of claim 24(1, further comprising dispensing the first thermoplastic polymer, the second thermoplastic polymer, or a third thennoplastic polymer through a third region of the die assembly such that a third portion of the mesh body is a second plastic mesh bolster.

242. The method of claim 240 or claim 241 , wherein the plastic mesh base comprises a first side edge, a second side edge, a front edge, a rear edge, a first face, and a second face and die first plastic mesh bolster is attached to the plastic mesh base at the first edge,

243. The method of claim 242, wherein the second plastic mesh bolster is attached to the plastic mesh base at the second edge.

244. The method of any of claims 221-243 or 245-297, wherein the first plurality of apertures of the first region defines a first open space per unit area and the one or more additional apertures of the second region defines a second open space per unit area in the second region such that the first open space per unit area is greater than the second open space per unit area.

245. The method of any of claims 221-244 or 246-297, further comprising heating a polymeric material to a molten state such that when it is received by the die assembly and dispensed through the die assembly it forms the molten polymeric filaments and/or the additional molten polymeric member.

246. The method of any of claims 221-245 or 247-297, further comprising surrounding the molten polymeric filaments with a heating arrangement operable to apply heat to the molten polymeric filaments.

247. The method of any of claims 221-246 or 248-297, further comprising introducing the molten polymeric filament and/or the additional molten polymeric member into a cooling bath to form the mesh body of interconnected polymer filament.

248. The method of any of claims 233-236, wherein the second medium is disposed in the cooling bath.

249. The method of any of claims 221-248 or 250-297, wherein the die assembly includes a die plate.

250. The method of any of claims 221-249 or 251-297, wherein the die assembly includes template.

251. The method of any of claims 221 -250 or 252-297, wherein cooling occurs after the molten polymeric filament leaves the die plate.

252. The method of any of claims 221-251 or 253-297, wherein the one or more additional apertures includes an aperture sized to match an overall perimeter of a product and the die assembly maintains the molten polymeric filaments within the overall perimeter of the product.

253. The method of any of claims 221-252 or 254-297, wherein there are more apertures per unit area in the first region than apertures per unit area in the second region.

254. The method of any of claims 221-253 or 255-297, wherein the first plurality of apertures comprises a larger diameter than the one or more additional apertures.

255. The method of any of claims 221-254 or 256-297, further comprising masking a portion of die plate with a template comprising a predefined outline such that the mesh body has a cross-section that is defined by the predefined outline.

256. The method of any of claims 221-255 or 257-297, wherein the second region includes a location that corresponds to a location of an occupant sensor in the mesh body.

257. The method of any of claims 221-256 or 258-297, wherein the second region corresponds to respective bolster areas of a cushion.

258. The method of any of claims 221-257 or 259-297, wherein the die assembly comprises a third region defining a second plurality of apertures, the third region defining a third ratio of a third blocked area to a third open area that is different than the first and/or second ratio.

259. The method of claim 258, wherein the third open area per unit area is less than the first and/or second area per unit area.

260. The method of any of claims 221-259 or 261-297, further comprising heating an entire perimeter of the molten polymeric filaments.

261. The method of any of claims 221-260 or 262-297, further comprising replacing the die assembly or a portion thereof with a second die assembly or portion thereof.

262. The method of any of claims 221-260 or 263-297, wherein the die assembly or a portion thereof includes an interchangeable die plate or template.

263. The method of any of claims 221-262 or 264-297, wherein the plurality of apertures forms a size or distribution gradient along the die assembly such that the mesh body comprises a hardness gradient.

264. The method of claim 241 or claim 258, wherein the third region of the die assembly is configured to provide a third portion of the mesh body having a third hardness that is greater than a second hardness of the second portion of the mesh body which is greater than a first hardness of the first portion of the mesh body.

265. The method of claim 264, wherein the second portion is disposed between the first and third portions.

266. The method of any of claims 241, 258, or 264-265, wherein the third portion has a hardness that is different than the second hardness and within 10% of the first hardness.

267. The method of any of claims 221-266 or 268-297, wherein the additional molten polymeric member is dispensed on an exterior surface of the mesh body.

268. The method of any of claims 230-232, further comprising dispensing the film on an exterior surface of the mesh body.

269. The method of any of claims 221-266 or 268-297, wherein the additional molten polymeric member is dispensed between at least two subsets of the interconnected polymeric filaments.

270. The method of any of claims 230-232, further comprising dispensing the film between at least two subsets of the interconnected polymeric filaments.

271. The method of any of claims 230-232, 268, or 270, further comprising forming an aperture through the film.

272. The method of any of claims 221-271 or 273-297, wherein the one or more additional apertures comprises a slit to dispense a film as the additional polymeric member.

273. The method of any of claims 221-272 or 274-297, further comprising removing the dispensing assembly or a portion thereof and installing a second dispensing assembly or portion thereof.

274. The method of claim 273, further comprising dispensing a different mesh body through the second dispensing assembly or portion thereof.

275. The method of any of claims 221-274 or 276, further comprising assembling a seat with the mesh body.

276. The method of any of claims 230-232 or 268, wherein the film is an impermeable film.

277. The method of any of claims 230-232, 268, or 276, further comprising attaching at least one of a seat trim, an actuator, and/or a heat transfer layer to the film.

278. The method of claim 246, wherein the heating arrangement comprises a rectangular heating structure to surround the molten polymeric filaments as the molten polymeric filaments leave the die assembly.

279. The method of any of claims 221-278 or 281-297, wherein a heating arrangement is attached to a side of the die assembly.

280. The method of any of claims 221-278 or 281-297, wherein a heating arrangement is attached to each side of the die assembly.

281. The method any of claims 221-280 or 282-297, wherein a die assembly is rectangular.

282. The method of any of claims 246 or 278-280, wherein the heating arrangement controls an air temperature around the molten polymeric filaments to a temperature of 60 to 140°C.

283. The method of any of claims 246, 278-280, or 282, wherein the heating arrangement is positioned at least 100 to 150 mm from the molten polymeric filaments.

284. The method of any of claims 221-283 or 285-297, wherein the molten polymeric filaments include an outer portion disposed toward an outside edge of the die assembly, and an inner portion disposed inward from the outer portion, and a heating arrangement configured to heat the outer portion such that bonding between the molten polymeric filaments of the outer portion is greater than bonding between the molten polymeric filaments of the inner portion.

285. The method of any of claims 221-284 or 286-297, wherein a first polymeric material is dispensed through the first region of the die assembly and a second polymeric material is dispensed through the second region of the die assembly, the second polymeric material being different than the first polymeric material.

286. The method of claim 285, wherein second polymeric material is introduced into the die assembly toward an outside edge of the die assembly and the first polymeric material is introduced into the die assembly inward from the second polymeric material such that the additional molten polymeric member at least partially surrounds the first polymeric filaments.

287. The method of any of claims 221 -286 or 288-297, further comprising dispensing a third polymeric material through the die assembly that is different than the first and/or second polymeric materials.

288. The method of claim 287, wherein the third polymeric material is different than the first and second polymeric material and the first and second polymeric materials are different from each other.

289. The method of any of claims 221-289 or 290-297, wherein the first plurality of apertures collectively has a greater area than the one or more additional apertures.

290. The method of any of claims 221-289 or 291-297, wherein the first plurality of apertures forms a plurality of nozzles and the method further comprises closing a plurality of nozzles or a subset thereof outside the one or more additional apertures.

291. The method of any of claims 221-290 or 292-297, further comprising cooling the die assembly.

292. The method of any of claims 221-291 or 293-297, further comprising providing a mold with the one or more additional apertures as the die assembly.

293. The method of claim 292, wherein the mold comprises cooling passage therethrough to cool the mesh body.

294. The method of claim 292 or claim 293, further comprising placing the mold in a cooling fluid, the cooling fluid cooling the mesh body.

295. The method of any of claims 221-294 or 296-297, wherein the mesh body further comprises a concave contoured perimeter.

296. A product formed by the method of any of claims 221-295.

297. A vehicle interior component formed by the method of any of claims 221-296.

298. A system comprising: a shaping assembly comprising a die plate, the die plate having a first region with a plurality of apertures and a second region with one or more additional apertures that are different than the plurality of apertures; an extruder to extrude one or more polymeric materials through the shaping assembly to form a mesh cushion body.

299. The system of claim 298, further comprising a template to block a portion of the apertures, a funnel to direct molten polymeric filaments extruded through the die plate into a unitary body and/or a cooling bath, a heating arrangement to heat the molten polymeric filaments, and/or conveyor assembly to convey the unitary body through the cooling bath.

300. The system of claim 298 or 299, wherein (i) the first region of the die plate defines a first closed portion and a first open space, and the second region defines a second closed portion and a second open space such that the first closed portion is different than the second closed portion and/or the first open space is different than the second open space, (ii) the first region defines a perimeter in the shape of a final product, (iii) the one or more additional apertures comprises a slit for dispensing a polymeric film, (iv) a first aperture density of the first region is different than a second aperture density of the second region, and/or (v) the size of the plurality of apertures is different than the size of the one or more additional apertures.

301. The system of any of claims 298-300, wherein the first region defines a first profile and the second region defines a second profile that is different than the first profile.