Three-dimensional mesh structures and method of assembly

Abstract

A seat cushion formed from a body comprising a plurality of extruded polymer filaments randomly connected to form a first three-dimensional mesh structure formed by the extruded polymer filaments. The body is formed by heating an area of the body with an ultrasonic tool that modifies a portion of the extruded polymer filaments to form a second three-dimensional structure comprising a second shape that is different than the first shape. A skin of extruded polymer film is welded to the body of extruded polymer filaments. A second body of a plurality of extruded polymer filaments randomly connected to form a second three-dimensional mesh structure formed by the extruded polymer filaments is welded to the first body. A method is disclosed for modifying the bodies with an ultrasonic tool to shape or weld the bodies.

Dependencies are inferred from the claim text.