Body support member with lattice structure

Abstract

A body support structure includes a structural lattice structure having a first stiffness and a compression lattice structure supported by the structural lattice structure and having a second stiffness less than the first stiffness. A skin lattice structure is supported by the compression lattice structure, wherein the skin lattice structure is resistant to shear deformation in response to a normal force and is expandable in a direction perpendicular to the normal force.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 902,187, filed on September 18, 2019, entitled “Body Support Member With Lattice Structure,” the entire disclosure of which is hereby incorporated by reference. Technical Field

[0003] The present application relates generally to body support structures such as chairs, and more particularly to body support structures including one or more lattice structures. Background Art

[0004] Body support structures, including, for example, office chairs, vehicle and aircraft seats, sofas, beds, and other furniture, are typically configured with internal or external support frames having hard contact points. For example, the seat and backrest may be made of a resilient membrane or shell structure, which is typically supported by a rigid peripheral frame surrounding the membrane or shell structure. The frame has hard contact points that prevent the backrest or seat from bending about its periphery, and may also prevent twisting or torsional movement about the longitudinal axis of the backrest or seat. In other chairs, the backrest or seat may be configured with a rigid central spine that allows some torsion about the longitudinal axis, but hard contact points are provided by the connection of the spine to the body support member. In yet another type of chair, the backrest or seat may be configured with a rigid outer shell that supports a cushion or other resilient body support member.

[0005] In many of these conventional seat structures, the rigidity of the frame or shell limits the ability of the body support structure to flex and support the user's body as the user moves within the seat structure. Additionally, the seat structure edges have hard contact points or lack of flexibility, coupled with the limitations imposed by the frame, spine and / or rigid shell, limiting the comfort and ergonomic responsiveness of the seat structure.

[0006] In addition, conventional chairs typically include multiple components and parts, including, for example, one or more backrests, seats, tilt controls, armrests, gas columns / springs, etc., each of which must be assembled separately and then assembled together into the final product structure. Often, sub-assemblies are manufactured at remote locations or by outside suppliers, which requires additional shipping, inventory and transportation costs, and relatively heavy metal parts may also increase these costs. For example, a conventional tilt control may contain dozens of parts, including multiple metal parts that must be stamped or cast and then assembled using multiple mechanical fasteners or welding. The manufacturing and assembly processes may involve complex and expensive tooling that is difficult to adjust and adapt to other components. Summary of the invention

[0007] The present invention is defined by the following claims, and nothing in this section should be taken as a limitation on those claims.

[0008] On the one hand, an embodiment of a body support structure includes a plurality of spaced-apart support members defining opposing first and second surfaces, wherein adjacent support members define an opening between the sides of adjacent support members. A plurality of spaced-apart base members defining opposing first and second surfaces, wherein the first surface of the base member faces the second surface of the support member and is spaced apart from the second surface of the support member, such that the plurality of support members and the plurality of base members define a space therebetween. Each base member is located below at least a portion of an opening defined by at least two adjacent support members, and adjacent base members define an opening between the sides of adjacent base members. A plurality of connectors extend through the space and connect each base member to at least two adjacent support members. Each connector defines a first acute angle relative to the second surface of the corresponding support member and a second acute angle relative to the first surface of the base member.

[0009] On the other hand, an embodiment of the body support structure includes an aspect array having a plurality of spaced apart support members arranged in multiple rows and columns. Each row has the same number (n1) of support members, and each column has the same number (n2) of support members. At least one row has a first width, and at least another row has a second width, wherein the first and second widths are different. At least one column has a first length, and at least another column has a second length, wherein the first and second lengths are different. The peripheral array defines a closed loop around the aspect array. The peripheral array includes first and second rows of spaced apart support members connected to the opposite outermost rows of the aspect array, and first and second columns connected to the opposite outermost columns of the aspect array. The first and second rows and the first and second columns of the peripheral array are connected, and wherein the first and second rows of the peripheral array include n1 support members, and wherein the first and second columns of the peripheral array include n2 support members. The support members in the aspect array and the peripheral array are connected.

[0010] In yet another aspect, an embodiment of a body support structure includes an aspect array having a plurality of spaced apart support members arranged in a plurality of rows and columns, wherein each row has n1 support members and wherein each column has n2 support members. The outermost portion of the aspect array has n3 support members, wherein n3=2*n1+(2*(n2-2)). At least one row has a first width and at least another row has a second width, wherein the first and second widths are different. At least one column has a first length and at least another column has a second length, wherein the first and second lengths are different. The peripheral array defines a closed loop surrounding and connecting the aspect array. The peripheral array includes first and second rows of spaced apart support members connected to opposite outermost rows of the aspect array, and first and second columns connected to opposite outermost columns of the aspect array. The first and second rows and the first and second columns of the peripheral array have n4 support members, wherein n4=(2*n2)+(2*n1). The support members in the aspect array and the peripheral array are connected.

[0011] In yet another aspect, an embodiment of a body support structure includes a structural lattice structure having a first stiffness, and a compression lattice structure supported by the structural lattice structure and having a second stiffness less than the first stiffness. The compression lattice structure can compress in response to a first normal force applied thereto. A skin lattice structure is supported by the compression lattice structure, wherein the skin lattice structure is resistant to shear deformation in response to a second normal force applied thereto, and wherein the skin lattice structure can expand in response to the second normal force applied thereto in a direction perpendicular to the second normal force applied thereto.

[0012] In yet another aspect, an embodiment of a body support structure includes a base structure, a body support member, and a support column. The support column includes first and second spaced apart ends coupled to the body support member and the base structure, respectively, and an intermediate compression lattice structure connected to the first and second ends. The first and second ends are movable between a nominal position and a compressed position, and the compression lattice structure is compressible between a nominal configuration and a compressed configuration corresponding to the nominal and compressed positions. When in the compressed configuration, the intermediate compression lattice structure applies a biasing force to the first and second ends.

[0013] In yet another aspect, an embodiment of a body support structure includes a base structure and a body support member coupled to the base structure. At least one of the base structure and the body support structure includes a lattice structure having integrated kinematic properties. In various embodiments, the integrated kinematic properties may include motion limiters, locking systems, component connectors, and / or biasing members.

[0014] In yet another aspect, an embodiment of a method of manufacturing any of the body support structures disclosed herein includes forming a structural lattice structure, a compressed lattice structure, and a skin lattice structure by additive manufacturing. In one embodiment, the additive manufacturing is performed by 3D printing. In one embodiment, the method includes integrally forming the structural lattice structure, the compressed lattice structure, and the skin lattice structure during a single 3D printing operation.

[0015] On the other hand, an embodiment of the body support structure includes a plurality of spaced apart support members, which define relative first and second surfaces, wherein adjacent support members define an opening between the sides of adjacent support members. A plurality of spaced apart base members, which define relative first and second surfaces, wherein the first surface of the base member faces the second surface of the support member and is spaced apart from the second surface of the support member, so that the plurality of support members and the plurality of base members define a space therebetween. Each base member is located below at least part of the opening defined by at least two adjacent support members, and the adjacent base members define an opening between the sides of the adjacent base members. A plurality of connecting legs extend through the space and connect each base member to at least four adjacent support members, and connect each support member to at least four adjacent base members. At least some of the connecting legs have a different length from other connecting legs, wherein the spacing between at least some of the connected support members and the base members is different from the spacing between other connected support members and the base members. The first region includes a longer connecting leg connecting the base member and the support member, and the second region includes a shorter connecting leg connecting the base member and the support member. The first and second regions may have different stiffnesses, for example the second region being stiffer than the first region.

[0016] In one embodiment, the edge portion connects and surrounds the base member and the support member. In one embodiment, the edge portion may taper.

[0017] Various embodiments of body support structures and methods provide significant advantages over other body support structures and methods of manufacturing and assembling the same. For example, but not limited to, the body support structure provides an integrally compliant structure that can be configured with soft interface portions, such as support portions located at the peripheral edges and along the front, thighs. In addition, changes to the configuration of one or more components, or the entire chair, can be made quickly and easily through software / programming changes rather than through complex and expensive reassembly. In fact, the need for tools can be completely eliminated. Because the entire body support structure can be manufactured at a single location, shipping costs can be greatly reduced, and such manufacturing locations are strategically located in various geographic locations close to end users or sales / delivery points.

[0018] The foregoing paragraphs are provided as a general introduction and are not intended to limit the scope of the following claims. Various preferred embodiments and further advantages will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a front perspective view of one embodiment of a body support structure.

[0020] Figure 2 yes Figure 1 A rear perspective view of the body support structure shown.

[0021] Figure 3 yes Figure 1 A right side view of a body support structure is shown, and the left side view is its mirror image.

[0022] Figure 4 yes Figure 1 A rear view of the body support structure is shown.

[0023] Figure 5 yes Figure 1 A front view of the body support structure is shown.

[0024] Figure 6 yes Figure 1 A bottom view of the body support structure is shown.

[0025] Figure 7 yes Figure 1 A top view of the body support structure is shown.

[0026] Figure 8 is a stereogram of a body support structure having a skinless lattice construction applied thereto.

[0027] Fig. 9 is a partial enlarged view of a portion of a body support structure, which includes a structural lattice structure and a compression lattice structure.

[0028] Fig.10 is a partial enlarged view of a portion of a back brace, which includes a structural lattice structure and a compression lattice structure.

[0029] Fig.11 is a rear perspective view of the first compression member.

[0030] Fig.12 yes Figure 1 A front perspective view of a first compression member is shown.

[0031] Fig.13 It is a three-dimensional diagram of the local body support structure, which includes various structural frame structures.

[0032] Fig.14 yes Fig.13 A side view of a body support structure is shown.

[0033] Fig.15 yes Fig.13 A bottom view of the body support structure is shown.

[0034] Fig.16 is an enlarged partial front view of a support column including a compressed lattice member.

[0035] Fig.17 is an enlarged partial rear view of a support column including a compressed lattice member.

[0036] Fig.18 is combined with Fig.16 and 17 Bottom perspective view of the compressed lattice structure in the pillar is shown.

[0037] Fig.19 is combined with Fig.16 and 17 A top perspective view of the compressed lattice structure in the struts is shown.

[0038] Fig. 20 is a rear view of one embodiment of a skin lattice construction.

[0039] Fig.21 yes Fig. 20 A bottom view of one embodiment of a skin lattice construction is shown.

[0040] Fig. 22 yes Fig. 20 A right side view of one embodiment of a skin lattice construction is shown, with the left side view being a mirror image thereof.

[0041] Fig.23 yes Fig. 20 A front perspective view of one embodiment of a skin lattice construction is shown.

[0042] Fig.24 yes Fig. 20 A top view of one embodiment of a skin lattice construction is shown.

[0043] Fig.25 yes Fig. 20 A front view of one embodiment of a skin lattice construction is shown.

[0044] Fig.26A yes Fig.23 A perspective top view of a detail of a corner of a skin lattice structure is shown.

[0045] Fig.26B yes Fig.23A bottom perspective view of a portion of a corner of a skin lattice structure is shown.

[0046] Fig.26C yes Fig. 20 A perspective top view of a detail of another corner of the skin lattice structure is shown.

[0047] Fig. 27 It is a partial side view of a skin lattice structure.

[0048] Fig.28 A partial view of a skin lattice structure.

[0049] Fig.29 is a partial view showing the structural lattice structure, the compression lattice structure, and the skin lattice structure that define the front portion of the body support structure.

[0050] Fig.30 is a schematic diagram of a grid core unit.

[0051] Fig.31 is a schematic diagram of a lattice core unit with faces.

[0052] Fig.32 It is a top view schematic diagram of the skin grid structure and the surrounding array.

[0053] Fig.33 An alternative embodiment of integrated kinematics is shown.

[0054] Fig.34 An alternative embodiment of integrated kinematics is shown.

[0055] Fig.35 is a flow chart showing the manufacturing steps for making the body support structure.

[0056] Fig.36 is an enlarged partial view of a support column including a compressed lattice structure.

[0057] Fig.37 is a perspective view of another embodiment of a chair including a leather lattice construction on the seat and back portions of the chair.

[0058] Fig.38 yes Fig.37 Front view of the backrest skin lattice structure shown.

[0059] Fig.39 yes Fig.38 A cross-sectional view of a portion of a backrest skin grid structure is shown.

[0060] Fig.40 yes Fig.37 A top view of the seat skin grid structure is shown.

[0061] Fig.41 yes Fig.37 Bottom view of the seat skin grid structure shown.

[0062] Fig.42 yes Fig.41 A bottom view of a portion of a corner of a seat skin grid structure is shown.

[0063] Fig.43 yes Fig.42 An enlarged bottom view of a portion of the seat skin grid structure is shown.

[0064] Fig.44 is a bottom view of an alternative embodiment of a seat skin grid construction.

[0065] Fig.45 is a schematic cross-sectional view of an alternative embodiment of a skin lattice construction.

[0066] Fig.46 is a schematic cross-sectional view of an alternative embodiment of a skin lattice construction.

[0067] Fig.47 is a schematic cross-sectional view of an alternative embodiment of a skin lattice construction.

[0068] Fig.48 A bottom view of one embodiment of a seat skin grid structure.

[0069] Fig.49 A rear view of one embodiment of a backrest skin lattice structure. DETAILED DESCRIPTION

[0070] It should be understood that the term "plurality" as used herein refers to two or more. Figure 1As shown, the term "longitudinal" used herein refers to, or relates to, a length or longitudinal direction 2, such as the direction from top to bottom of the backrest 8 or from front to back of the seat 6, or vice versa (from bottom to top, and from back to front). The term "lateral" used herein refers to being located in the direction 4 from one side to the other side of the backrest or seat, or pointing to that direction, or extending along that direction. The term "coupled" refers to a direct or indirect connection or engagement, such as through an intermediate member, and does not require the engagement to be fixed or permanent, although it may also be fixed or permanent. The terms "first", "second", etc. used herein do not refer to specific components or features assigned to such designated terms, but to such components and features in accordance with the numerical order mentioned, which means that the component or feature designated as "first" may also be after the "second" such component or feature, depending on the order in which it is cited. It should also be understood that the designation of "first" and "second" does not necessarily mean that the two components, features or values ​​designated in this way are different, which means that, for example, the first direction can be the same as the second direction, and are simply applied to different components or functions respectively. The terms "upper", "lower", "back", "front", "front", "back", "vertical", "horizontal" and variations or derivatives thereof refer to Figure 1 and 2 The phrase "body support structure" refers to a structure that supports the body, including but not limited to office furniture, home furniture, outdoor furniture, and vehicle seating, including seating in automobiles, airlines, ships, and passenger trains, and may include but not limited to beds, chairs, sofas, stools, and other furniture components or other types of seating structures. Directions X, Y, and Z are defined as follows: Figure 1 As shown: the Z direction is perpendicular to the seat and the backrest, the X direction coincides with the lateral direction 4 of the seat and the backrest, and the Y direction coincides with the longitudinal direction 2 of the seat and the backrest.

[0071] Grid structure:

[0072] The term "lattice" refers to a three-dimensional structure having a matrix of nodes 16 and struts / beams / legs 18 extending between and connecting the nodes 16 (see Fig.30 ), the nodes and struts are arranged to provide high strength and low weight mechanical properties, which provides significant weight reduction while maintaining the necessary overall structural integrity. The lattice construction provides excellent ventilation and air flow performance. The various components of the body support structure 32 can include lattice areas, as well as other areas that can remain solid or non-lattice, as further described below.

[0073] The core units 12, or cells, of the grid, e.g. Fig.19As shown, the overall lattice structure can be defined by continuous repetition. Some exemplary unit structures are cubes, stars, octagons, hexagons, rhombuses and tetrahedrons. The unit structures can be changed or adjusted individually, as well as integrated or mixed, to achieve the response, shape and overall performance required for the lattice structure. Some unit structures may have a higher stiffness-to-weight ratio, while others may provide other properties, such as the ability to absorb or suppress energy. The size and density of the unit refers to the size of a single unit and how many units are repeated in a space. The size of the unit is a function of the size of the node and beam / leg (e.g., thickness and length). The material and density of the lattice structure, as well as the orientation of the unit and structure, may have an impact on the properties of the lattice. The intrinsic structural properties of the lattice depend on the configuration of the unit cell, which includes the size and shape of the legs, the overall size of the unit and the density of the unit. In a preferred embodiment, the lattice structure is subject to the shape of the structure, which means that the orientation of the unit can be changed to adapt to the expected properties. For example, a compression lattice structure is oriented in the seat area to provide compressibility in the vertical direction, but oriented in the back direction to provide compressibility in the horizontal direction, so that loads are absorbed in the Z direction of the seat and back. In this way, the orientation of the lattice structure conforms to the shape of the seat / back and changes as the lattice structure fills any geometric shape. The lattice is thus aligned with the load / stress direction, which improves the overall structural performance of the structure.

[0074] The inherently complex nature of the lattice makes it well suited for additive manufacturing, which can be achieved, for example, by 3D printing. Some exemplary 3D printing technologies include fused deposition modeling (FDM), stereolithography (SLA), digital light processing (DLP), selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EMB), laminated object manufacturing (LOM), binder jetting (BJ), digital light synthesis (DLS), multi-jet fusion (MJF), digital light synthesis (DLS), multi-jet fusion (MJF), and material jetting / wax casting.

[0075] like Fig.30 As shown, for example, the compressed lattice structure may include three intersecting and orthogonal rectangles 16, 18, 20, which define nodes 22 at the four corners of the first rectangle 18, a pair of nodes 26 at the intersection of the other two rectangles 16, 20, and a pair of beams 24 extending between each corner node 22 and node pair 26. Fig. 20 As shown, the faceted core element further includes a pair of nodes 28 disposed along two corners of one of the other rectangles 16 , with a beam 30 extending between the corner nodes 22 , 28 .

[0076] Body support structure

[0077] With reference to the accompanying drawings, Figure 1-1729 show an embodiment of a body support structure 32 configured as a chair having a base 34, a seat 6, and a backrest 8. The base 34 includes a base 36 having a bottom platform 38 joined to a floor 40, and a column 42 extending upward from the platform 38. The platform 38 has a generally horizontal orientation and has a front edge 44 that tapers rearwardly from a centerline vertex 46. In one embodiment, the front edge defines the frontmost boundary or surface of the body support structure, while in another embodiment, the front edge 48 of the seat 6 defines the frontmost boundary of the body support structure. The column 42 includes a lower portion 50 extending rearwardly and upwardly from the front edge 44 and an upper portion 52 extending forwardly and upwardly from the lower portion 50. The lower portion has a first width (W1) adjacent to the front edge and a second width (W2) adjacent to a joint 54 to which the upper portion is connected, the second width (W2) being less than the first width (W1). The lower and upper portions both have front surfaces tapering rearwardly from the plane 101 where the front centerline YZ lies, such that the upper and lower portions have a generally triangular cross-sectional shape. The tapering of the front surface and front edge 44 of the lower portion 50 provides more contact for the user's feet and legs. At the same time, the cross-sectional shape of the column with a prominent centerline vertex 58 provides more resistance to bending about the horizontal, laterally extending X-axis. From a side view, the column and base define a generally L-shape, which forms an open space below the seat 6.

[0078] The seat support 60 is connected to the base along the top end 68 of the upper portion 52 of the column 42. The seat support includes a pair of spaced apart beams 62 defining an opening 148 therebetween and a pair of U-shaped or V-shaped connectors 64 connecting the front portion 66 of each beam to the upper portion 52. The connectors 64 can be flared outward and define a first flexure region 210 or flexible joint, thereby allowing the rigid and flexure-resistant beams 62 to pivot relative to the base 34 (particularly the column 42) about a horizontal, laterally extending X-axis. The beams 62 of the seat support are cantilevered rearwardly from the connectors 64 and the flexure region 210.

[0079] The back frame 70 is connected to the seat support along the rear portion 72 of the beam 62 and extends upwardly from the seat support 60, and has a pair of laterally spaced uprights 74 defining an opening 150 therebetween, and an upper cross member 76 connecting the upper ends of the uprights 74. The uprights 74 are connected to the rear portion 72 of the beam by a curved transition region 78 that defines a second curved region 212 or a flexible joint to allow the back frame 70 to pivot relative to the seat support 60. Figure 2 , 4, 8 and 10, the upper portion 80 of the pillar and the cross member 76 have a greater width and thickness, making these portions stiffer than the lower portion 82 of the pillar. The interface between the upper and lower portions defines a recess 84 having a depth (D1) that is filled with a compressive layer that is arranged flush with the front surface of the pillar 74, as further described below.

[0080] refer to Figure 1-4 , 8, 9, 16, 17 and 36, the support column 86 is disposed or extends between the base 34 and one of the seat support 60 and / or the backrest frame 70, and includes the transition area 78. The support column includes a lower portion 88 and an upper portion 90. Figure 3 As shown, the lower end 92 of the support post or its lower portion is connected to the upright at the joint 54 between the upper and lower portions of the upright, and the support post 86 is inclined at an angle α, which is generally in the same direction as the direction of the lower portion 50 relative to the platform 38, or the horizontal plane defined by the floor, so that the axial load applied by the support post 86 is effectively transferred to the lower portion 50 and then to the platform 38. The support post or its upper portion is connected to the seat support 60, and in particular to the spaced beams 62 in front of the transition area 78. The support post is generally integral and extends along the centerline of the body support structure, although it should be understood that it can also be configured as two or more laterally spaced support posts that are respectively connected to the beams. The support post 86 spans the distance between the beams 62, thereby providing lateral stability to the beams, while also supporting the rear region of the beams 62, which is longitudinally spaced rearward from the curved region 210 defined by the connector 64. The upper and lower portions 88, 90 of the support column are spaced apart, with one of the upper and lower portions having a column or guide member 96 extending into a channel or track 98 opened in the other of the upper and lower portions. The respective ends of the upper and lower portions facing each other can be provided with a cover or other support surface 104, 106.

[0081] An interface member 144 is secured across openings 148 , 150 defined between the beam 62 of the seat support and the uprights 74 of the back frame to define the seating surfaces of the seat 6 and back 8 .

[0082] Structural character frame construction

[0083] Each of the base 34, the support posts 86, the seat supports 60 and the backrest frame 70 may be formed entirely or at least partially of a structural lattice structure 108. A structural lattice structure is a relatively stiff, bending-resistant structure, while a compression lattice structure is a non-bending-resistant structure that is compliant and, while not stiff, absorbs energy well when compressed. A structural lattice structure has a first stiffness, which is the displacement measured along a degree of freedom (translation or bending) in response to an applied force. The stiffness is determined or defined by the lattice configuration and the material, such as the total moment of inertia of the assembly or its cross-section, and the Young's modulus of elasticity associated with the material. When the lattice structure is loaded, whether in compression or bending, the structural lattice structure may undergo some elastic deformation, but remains relatively rigid outside of a predetermined bending region that is purposefully designed to allow bending and extension. The structural lattice structure is also conformable, which means that the configuration and orientation of the cells and lattices follow or conform to any external geometry of the assembly and are optimized to align with the stresses and loads applied to the structure.

[0084] like Figure 1-6 As shown, the structural lattice construction 108 defining the platform and some portions of the lower and upper columns 50, 52 follow a lateral gradient in the lateral direction 2, wherein the lattice construction is very open, with larger spaces between nodes along the centerline plane 101 of the columns and platform; and a more closed configuration, with smaller spaces between nodes along the side edges 103 and rear edge 105 of the platform, and along the side edges 107 of the columns 42, with the size of the cells gradually decreasing along the gradient. Solid (non-lattice) portions may also be interconnected with the lattice portions, with the positions of the solid (non-lattice) portions providing additional strength, or being positioned so that the various components can be manufactured separately, such as by 3D printing, and then assembled and connected. The solid (non-lattice) portions may contain connecting geometry and may be configured with an internal lattice construction surrounded by a solid outer wall.

[0085] In one embodiment, if Figure 1-5As shown in FIGS. 8-10 and 13-15, non-lattice structures 64, 100, 102 are located between portions of the structural lattice structure such that the structural lattice structure is discontinuous, such as non-lattice structures 100 being disposed between portions of the structural lattice structure of the upper and lower portions 50, 52 of the columns, even though the components are a single homogenous, integrally formed unit. Specifically, portions of the bottom platform 38 and the lower and upper portions 50, 52 of the columns are made of structural lattice structure, while the non-lattice structure 100 defines transition areas between the upper and lower portions of the columns, as well as the lower ends of the columns and stanchions, and between the bearing surfaces 104, 106, guides 96, and rails 98. Similarly, connector 64 may be made of non-lattice structure, as may joints or transition portions 102 between the upper ends of the stanchions and the seat support beams, and portions of beam 62. Non-lattice construction is stronger than structural lattice construction and is well suited for the high loads and stresses due to bending that may be encountered at various joint interfaces between components. The non-lattice construction may include a solid or tubular structure including, for example, one or more central openings having a surrounding peripheral wall. In one embodiment, the structural lattice construction and the non-lattice construction have the same outermost profile, with their outermost surfaces being flush. The structural lattice construction and the non-lattice construction may be made of the same material and used as a single, integral, homogenous component, such as by additive manufacturing, including 3-D printing as further explained below. In one embodiment, the structural lattice construction is made of polyethylene or other relatively stiff material such as metal. Other materials include thermoplastic elastomers, such as TPE and TPU. In one embodiment, the structural lattice construction is made of 30% GF nylon with a Young's modulus of 700 ksi or greater. The structural lattice construction and / or the non-lattice construction provide independent compliance, or are configured to provide specific flex regions / compliant joints to allow movement between components, such as between a seat and a base, or between a backrest and a seat, while maintaining rigidity and stiffness in other areas and ranges. The structural lattice construction may include a core unit and a core unit having a face formed along its outermost surface, such as Fig.30 and 31 As shown, the orientation of the core units is arranged so that the structural lattice structure is rigid and oriented to carry loads applied thereto, for example having properties similar to those of an injection molded component.

[0086] Compressed lattice construction

[0087] refer to Figure 1-1216, the seat 6 and backrest 8 also include a first compression member 110 having: a pair of laterally spaced beams 114 that overlie and are supported by the seat support beams 62; a pair of laterally spaced uprights 116 that extend laterally to the beams 114 and upwardly along the front surface of the back frame uprights 74; and a front cross-beam 118 that extends laterally between the front ends of the cross-beams 114 near the front of the seat. Thus, the compression member has a lower U-shaped portion from which a pair of uprights extend upwardly and define a general forklift frame shape with tines defined by the uprights 116. The uprights 116 fill the recesses 84 formed by the back frame uprights and provide a flush surface with the upper portion 80 of the rear frame 70.

[0088] refer to Figure 1-4 , 16-19 and 36, the second compression member 120 is disposed between the upper and lower portions 88, 90 of the pillars and has upper and lower surfaces 122, 124 adjacent to the bearing surfaces 104, 106. The second compression member layer has a central through hole 126 through which the guide 96 is disposed.

[0089] The first and second compression layers are made of a compression lattice structure 112, which is supported by (or located between) a structural lattice structure and / or a solid structure as described above. The compression layer has a second stiffness that is less than the first stiffness, which means that the compression layer will undergo or withstand a greater degree of displacement or deflection in at least one direction in response to the same force applied to a material sample of the same size in at least one direction. In some embodiments, the first stiffness is many times greater than the second stiffness. In some embodiments, the second stiffness is 50% or less of the first stiffness. For example, the stiffness is variable, for example, the compressibility of the lattice structure can be higher, and the method is to change the orientation of the lattice structure so that the diamond unit structure ( Fig.30 ) is perpendicular to a load FN which is perpendicular to the surface. In other words, the stiffness is a function of the load direction and the lattice direction, the lattice construction dimensions (e.g., the diameter of the beam), the voxel density (node ​​density), and the Young's modulus associated with the material that makes up the lattice construction. Some exemplary materials are thermoplastic polyurethanes (TPUs), and can have a Young's modulus of 200 ksi or less, and in one embodiment 100 ksi or less, while having a compression lattice construction with compression properties similar to some foams. The compression lattice construction provides distributed compliance. The compression lattice construction is compressible in response to a normal force FN applied thereto, such as by the upper and lower bearing surfaces 104, 106 of the struts, or by a person sitting such as Figure 4 , 8 and applied by a user on the seat shown in 16. Figure 1-12As shown in Figures 16, a compression lattice structure, such as a beam, includes a cell matrix having a first portion 126 having one or more layers of unit cells and a second portion 128 having multiple layers of unit cells, wherein the second portion has more layers of unit cells than the first portion, and includes a transition zone 130 between the first and second portions. For example, the front and cross members of the beam have a large number of layers to provide a greater degree of compressive displacement in response to a normal load applied thereto.

[0090] refer to Figure 1-4 , 16-19 and 36, the second compression member 120 acts as a spring that is compressed when a user sits on and reclines in the chair, and the upper and lower support portions 88, 90 formed of a structural lattice structure and / or solid components compress the spring between the bearing surfaces when the guide 96 moves within the track 98. The second compression member provides a biasing force to resist the tilt of the seat and biases the upper and lower portions of the support away from each other to return the seat to a standard position when unloaded. In particular, the second compression member defined by the intermediate compression lattice structure is connected to the first and second ends of the relatively rigid upper and lower portions 88, 90 of the support, and the first and second ends are movable between a standard position and a compressed position. The intermediate compression lattice structure is compressible between a standard configuration and a compressed configuration corresponding to the standard and compressed positions, wherein the intermediate compression lattice structure applies a biasing force to the first and second ends when in the compressed configuration. The brace will also provide a maximum recline / recline tilt position when the second compression member reaches maximum compression and bottoms out between the support surfaces 104, 106.

[0091] Thus, the strut 86 including the second compression member 129 has integrated kinematics, which are defined as features that affect or control the motion of a body or body system, including, for example, but not limited to, biasing two or more bodies toward or away from each other, limiting movement between two or more bodies, and / or locking two bodies in one or more relative positions. It should be understood that the integrated kinematics may include one or both of, or consist of one or more of, the structural lattice construction, the solid construction, the compression lattice construction, and / or the skin lattice construction discussed below.

[0092] The lattice structure may include various integrated kinematic features, such as a second compression member 120 that acts as a biasing member. Fig.33 and 34 , the integrated kinematics may include a motion limiter, such as a tilt limiter, having a compression member 134 (lattice structure); when adjacent lattice structures 136, 138 abut ( Fig.34), or when an extendable lattice structure (same as a compression lattice structure, but expands in response to a stretching force) reaches maximum extension, the motion limiter bottoms out. This integrated kinematic feature can be any lattice structure, including structural and compression lattice structures as defined herein.

[0093] The compressed lattice structure may include a core unit and a plurality of units along the Fig.30 and 31 A core unit with its outermost surface shown.

[0094] Skin lattice structure

[0095] refer to Figure 1-7 , 20-29 and 37-49, the user interface member 144, 344, or skin member, is connected to the upper and front surface of the compression member 110 and the front surface of the upper portion 80 of the back frame. It should be understood that in alternative embodiments, a covering can be located on the user interface layer, such as a decorative fabric, and can include a foam layer disposed between the covering and the user interface member. The skin member 144, 344 spans the openings 148, 150 between the beams and between the posts and forms a seat member 201 and a back member 203 with a concave transition area 205 therebetween that defines a seating surface. As shown in FIG. Fig.37 As shown, the skin member 344 can be coupled to a non-grid frame, such as a seat frame 360 ​​or a back frame 362, either of which can include laterally spaced opposite side members 364 (uprights 366 on the back) and longitudinally spaced front and rear members (top and bottom members on the back), with the side / upright, front / bottom and rear / top members forming a ring. The skin member 344 can alternatively be fixed only to the side (upright) members, only to the front (bottom) and rear (top) members, and the side / upright, front / bottom and rear / top members, or any combination of these members. In the illustrated embodiment, separate seat and back skin members are attached to the seat and back frames, respectively. The skin members 144, 344 are made of a skin grid structure 146 that resists shear deformation in response to a normal load FN applied thereto. Thus, the skin lattice structure can absorb the weight of the user and transfer it through the openings 148, 150 to the spaced beam members 62, 114, 364 and / or the spaced columns 74, 116, 366. At the same time, the skin lattice structure is expandable in the transverse X and longitudinal Y directions perpendicular to the second normal force applied in the Z direction, so that the skin lattice structure can deflect while transferring the loads applied by the user to the beams and columns. At least a portion of the skin lattice structure covering the openings 148 between the transversely spaced beams and the openings 150 between the transversely spaced columns is not supported by any other structure.

[0096] refer to Figure 20-29 and 37-49, the skin lattice structure includes first and second layers 152, 154 connected to a plurality of connectors 156. In one embodiment, the skin lattice structure includes a plurality of spaced apart support members 158 facing the user's body, and a plurality of spaced apart base members 160 facing away from the user, and the plurality of connectors 156 or legs connect the support members to the base members. The first layer 152 includes a plurality of support members 158, which define opposing first and second surfaces 162, 164 facing toward and away from the user's body. Adjacent support members define openings 166 between sides of adjacent support members.

[0097] The second layer 154 includes a plurality of spaced-apart base members 160 defining first and second surfaces 168, 170 facing and facing away from the user's body. The first surface 168 of the base member faces the second surface 164 of the support member and is spaced from the second surface 164 so that the plurality of support members and the plurality of base portions define a space 174 between them. Each base member 160 is located below at least a portion of the opening 166 defined by at least two (preferably 3 or 4) adjacent support members 158, and is also located below a portion of the adjacent support members 158. Adjacent base members define openings 176 between the sides of adjacent base members. A portion of the opening 176 is located below a portion of the opening 166, and a through opening 181 extending through the entire skin lattice structure is provided between the sides of the base member and the sides of the support member. A plurality of connectors 156 pass through the space and extend each base member 160 and connect to at least two adjacent support members 158, for example, at the corresponding corners of each support member and the base member. The support members and the base member are offset from each other by 1 / 2 unit in both the X and Y directions. In one embodiment, each connector 156 defines a first acute angle θ1 relative to the second surface of the corresponding support member and a second acute angle θ2 relative to the first surface of the base portion, and in one embodiment θ1 and θ2 are equal. The connector opens an angle along the direction away from the corner and toward the center line of the corresponding support member and the base member to which they are attached, forming an angle β (e.g., 45 or 135 degrees) with the side edge of the support member and / or the base member. By orienting the connector to an angle toward the center line, the width of the space or opening 166 between the support members and the width of the space or opening 176 between the base members can be minimized, so that the surface 168 that is as continuous as possible is provided while allowing debris to pass through the openings 166, 176. For example, the width of the openings 166 and 176 can be equal to or greater than 0.5mm. In addition, the connector 156 is longer than the connector extending perpendicular to the base when the opening angle is opened, and supports the member at specific intervals. The longer connector 156, combined with its angle, can provide greater connector flexibility and allow for flexibility / expandability of the skin member 144, 344. Skin members with angled connectors can be formed using additive manufacturing techniques. In contrast, when the connector 156 extends substantially normal relative to (e.g., perpendicular to) the base and support members, such as Fig.39 As shown, skin member 344 may be more easily manufactured by conventional molding techniques, such as injection molding.

[0098] The skin lattice structure 146 provides distributed compliance. The connectors 156 are elastic and can be elastically deformed to allow relative movement between the connected support members 158 and the base members 160. For example, the skin lattice structure can compress and expand within a surface (e.g., a plane) in response to a translational force (generated by the application of a normal force) so that the seat structure exhibits flexibility within the plane of the array; however, it should be understood that the surface can be curved into a saddle shape in two directions, or curved into a bow shape in one direction, for example, so that the translational force is tangential to the surface at any particular location. In particular, the connectors 156 are elastically deformed to provide relative expansion / compression. Compression or expansion can occur simultaneously in the longitudinal and / or transverse directions, or other directions, depending on the arrangement of the array including the connectors. Deformation of the connector can be achieved by one or both of the geometry and / or material of the connector.

[0099] The skin lattice construction 146 may also be flexible or undergo bending and / or twisting / torsion deformation in response to bending and torsional forces. Bending and twisting may occur simultaneously about various longitudinal and / or transverse axes (located within or tangential to the curved surface) or about other tangential axes, depending on the arrangement of the array including the connectors. In contrast, the skin lattice construction is relatively stiff and resists deformation in response to, for example, shear forces FN applied along the normal or perpendicular to the curved surface. The skin lattice construction 146 may be made of a material that is stiffer than the compression lattice construction, such as polypropylene or rigid TPU, having a Young's modulus of 200-300 ksi in one embodiment, or a modulus greater than the modulus of the compression lattice construction and less than the modulus of the structural lattice construction.

[0100] The terms "elastic" or "elastically deformable" and variations or derivatives thereof refer to the ability of a body, such as a connector, to resist distorting influences or stresses and to return to its original size and shape when the stresses are removed. Thus, the connector 156 preferably does not undergo any plastic (e.g., permanent) deformation. The support member and base member may also undergo some elastic deformation, although the primary deformation or deflection, whether translational or pivoting / bending / torsion, is achieved through deformation of the connector 156.

[0101] The outer surface 162 of the support members 158 is flush, although the entire surface of the skin lattice structure may define a curved, non-planar outer surface. Thus, despite the openings 166 formed between the support members, the outer (body-facing) surface 162 will present a smooth surface to the user both visually and tactilely. As shown, the outer surface of the skin lattice structure has a convex front setback portion 180, a convex backrest upper edge portion 182, a concave transition portion 184, and concave seat and backrest member portions.

[0102] refer to Figure 26A-29 and 39, the connector 156 is an elongated shape, shown as a straight leg, which connects the inner portion of the support member, such as the second surface, and the inner portion of the base member, such as the first surface. For example, each base member 160 can be located below the four corners of adjacent support members 158, and the corners of each base member are connected to the corners of adjacent support members. In this embodiment, four adjacent support members define an opening 166, which is defined between their sides, has a cross or X-shaped shape, and covers the base member 160 connected thereto. In one embodiment, at least some of the support members and / or base members have a quadrilateral shape; and in one embodiment, all of the support members and base members have a quadrilateral shape. In one embodiment, at least some of the support members and / or base members have a rectangular shape, which in one embodiment can be defined as a square.

[0103] like Figure 13-15 As shown, at least some, and preferably all, of the base members 160 have through holes 172 formed in the central portion thereof, the through holes 172 being located at least below some of the portions defined by at least two, and preferably four, adjacent support members 158, and also below a portion of the openings 166. Thus, the through holes 172, 181 provide additional ventilation while also providing an outlet for debris (solid or liquid) deposited or spilled on the skin grid structure, which outlet passes through the openings 166 between adjacent support members and also through the through holes 172, 181. In one embodiment, at least some of the first and second surfaces of the support members and the base member may be planar, while in other embodiments, at least some of the first and second surfaces of the support members and the base member may be curved.

[0104] The connectors 156, in combination with the support members and the base members, allow or provide for torsional or twisting deformation of the skin lattice structure while limiting or preventing movement, such as shear and movement perpendicular to the surface. As shown, the connector can be configured to connect to four legs 156 of four support members to which the base members are connected. Similarly, the connectors, in combination with the openings 166 between the support members and the openings 176 between the base members, allow for various degrees of freedom of movement, including translation (compression / expansion), bending, and / or twisting / torsion. It should be understood that a connector having three legs 156 can also connect three support members, such as Fig.42 As shown, it has a Fig.40 The triangular base member 161 is shown below three adjacent support members 163. Fig.43As shown, the space between other base members adjacent to the base member 161 can be simply filled, thereby connecting the adjacent base members and eliminating the connector legs 156, while covering the through hole 181 between the base member 161 and the support member 163. In fact, various connectors can be configured to connect any number (2, 3, 4, ..., n) of adjacent support members. The support members 158 can have different widths and can be spaced apart by larger or smaller distances to define openings 166 of different sizes.

[0105] refer to Figure 20-29 , 32, 38 and 40, the skin lattice structure, in particular the first layer 152, includes a central facet array 186, the periphery of which is bounded by a peripheral array 188. The peripheral array 188 defines a closed ring around the entire peripheral area of ​​the central facet array 186. In one embodiment, the facet array 186 includes a plurality of rows 190, 190', 190", 190'", (e.g., in Fig.21 4 lines in the display)…190 n and a plurality of columns 192, 192', 192", 192'", (e.g. Fig.21 Displayed as four columns in the ...192 n A plurality of spaced-apart support members 158 are provided, wherein each row has the same number (n1) of support members, and wherein each column has the same number (n2) of support members. It should be understood that the number of rows can be any value and can be different from the number of columns, which can be any value. In addition, at least one row has a first width (W3) and at least another row has a second width (W4), wherein the first width and the second width are different. Similarly, at least one column has a first length (L1) and at least another column has a second length (L2), wherein the first and second lengths are different. It should be understood that Fig.21 The illustration shows rows with equal width and columns with equal length, but these can be changed, e.g. Figure 1-7 , 20-29, 38 and 40. Thus, when viewed from the Z direction, the skin lattice structure can be configured to have curved side edges, a curved front edge and a curved rear / upper edge. In addition, the facet array can be non-planar in the X and Y directions, and at least some of the rows and at least some of the columns can be non-linear or linear.

[0106] refer to Figure 20-29, 32 and 40, the peripheral array 188 includes at least a first closed loop 194, which has first and second rows 196, 196' of spaced-apart support members connected to the opposite outermost rows 190, 190"' of the aspect array 186; it also has first and second columns 198, 198' connected to the opposite outermost columns 192, 192"' of the aspect array 186. The first and second rows 196, 196' and the first and second columns 198, 198' of the peripheral array are connected to define the closed loop 194. In this way, the first and second rows of the peripheral array include n1 support members, or the same number of rows as the aspect array; and the first and second columns of the peripheral array include n2 support members, or the same number of columns as the aspect array. The support members 158 in the aspect array and the peripheral array are connected by connectors 156 and the base member 160 below.

[0107] In one embodiment, the perimeter array 188 has a plurality of rings. Figures 26A-27 wherein each ring has n1 support members in the first and second rows and n2 support members in the first and second columns; the peripheral ring has at least one pair of first and second rows, shown as three, and at least one pair of first and second columns, shown as three, or as Fig.40 As can be appreciated, the corners of the perimeter array include a pair of corner support members 200 connected to the corner support members 202 of the aspect array, which means that three connectors are required to connect the aspect array corner support members to the perimeter array corner support members, as shown in FIG. Fig.26B and 42 As additional perimeter array rings are added, the perimeter corner support members are enlarged to form the curved corners of the skin lattice construction, but the number of support members in each ring (combined from each row and column) is the same. It should be understood that the perimeter array can have one, two, or three or more rings 194. In this way, the skin lattice construction can be configured with gently curved corners, with relatively large radii or curvatures, which would otherwise not be achievable.

[0108] In other words, the outermost perimeter of the aspect array 186 includes n3 support members, where n3=2*n1+(2*(n2-2)). The closed ring 194 of the perimeter array has n4 support members, where n4=(2*n2)+(2*n1). Likewise, the perimeter array can include more than one ring, with each additional ring having the same number of support members. For example, a second perimeter ring can surround and connect to the first ring, where the second ring has n5 support members, and n5=n4.

[0109] refer to Figure 27-42As shown in Figures 44-47, the outermost ring of the peripheral array transitions to a solid or single-layer edge portion 370. The edge portion 370 can be made of a flexible material, or can be rigid and fixed to the frame 360, 362 below, whether it is solid or made of a structural or compressed lattice structure. For example, the edge portion can be fixed to one of the frames 360, 362 below. If not supported by the frame, the edge portion can provide a flexible peripheral member that contacts the user, such as along the front of the seat, where the front of the seat supports the user's thighs or the top of the backrest. The edge portion can taper from a thicker inner area to a thinner outer area. When the peripheral array transitions to the edge portion, some residual slits 390, 392 are formed between the support member and the base member. The edge portion can also include a circumferential or peripheral rim 396 or shoulder, such as extending downward from its bottom surface and extending around the entire edge portion or only some of it. The rim or shoulder provides an interface for attaching the fabric covering the top surface of the skin member, and any cushioning disposed on top thereof, such as by sewing, adhesive or other type of attachment.

[0110] In an alternative embodiment, if Fig.44 As shown, the corners of the skin lattice structure are configured with bifurcated corner arrays. The central array can have a cross shape, in which a plurality of longitudinally extending columns 402 intersect with a plurality of transversely extending rows 404. The array includes a central area 406, a pair of spaced-apart longitudinal areas 408, 410, and a pair of spaced-apart transverse areas 412, 414, each row (404, 408, 410) in each area has the same number of base members and / or support members in the area, and each column 402, 412, 414 in each area has the same number of base members and / or support members in the area. Each corner array includes a plurality of bifurcated areas (e.g., B1, B2, B3...). In the first bifurcated area, the corner base member or support member 420 has an outer side connected to a plurality of first peripheral arrays 422, for example including two base members or support members bifurcated from or connected to each side, i.e. a total of four base or support members. The first area B1 may include one or more first peripheral arrays, in Fig.44 In the second bifurcated area B2, each base or support member in the first peripheral array has an outer side connected to multiple second peripheral arrays 424, for example, including two bases or support members bifurcated from each side or connected to each side, that is, a total of eight bases or support members. The second area B2 may include one or more second peripheral arrays, such as Fig.44In the third bifurcated region B3, each base or support element in the second peripheral array has an outer side connected to a plurality of third peripheral arrays 426, for example including two bases or support members bifurcating from each side or connected to each side, i.e., a total of sixteen bases or support members. The third region B3 may include one or more third peripheral arrays, such as Fig.44 It should be understood that although Fig.44 The area shown in Fig.44 A 2:1 bifurcation between regions Bl, B2, B3 is included, but other ratios, such as 3:1 or greater, may also be suitable.A rim portion surrounds the array and is in-moulded with the array.

[0111] refer to Figure 45-49 , the cross-sectional configuration or depth of the skin lattice structure varies in the lateral and / or longitudinal directions, and the legs 156 have variable lengths (e.g., 11 vs. 12), which results in the skin lattice structure having variable stiffness. The central region 482 can have legs 156 of uniform length (11), while the edge portion 480 is tapered, with the legs 156 gradually becoming shorter as they approach the edge portion. Different regions can be configured with legs 156 of different lengths to allow those regions to have greater or lesser stiffness, for example, longer legs are located in a range or region (434, 436, 438) with a desired lower stiffness, while shorter legs are located in a range or region (430, 432) with a desired greater stiffness. For example Fig.48 As shown, for example, when supporting the buttocks of a user in a seat structure, the hardness of region 434 can be made lower than that of other regions 430. Fig.49 As shown, by varying the length and / or material of the legs 156, for example, a back strap 460 extending transversely in the lumbar region of the backrest can be further made stiffer than an adjacent region 470. Likewise, any portion 450 of the body support member can be made stiffer (or softer) than other surrounding / adjacent regions 470. Finally, the legs 156 can be shortened to provide a visible design (e.g., 450) on the top / bottom or front / back of the skin lattice structure. The design can take any shape or form, for example, the visible design 450 can resemble or illustrate a symbol (e.g., alphanumeric characters), a picture, a brand or company logo, which is an integral part of the structure and embedded in the structure.

[0112] manufacture

[0113] The structural lattice structure 108 (and non-lattice structures 100, 102), the compression lattice structure 134, and the skin lattice structure 146 can each be manufactured individually and collectively by additive manufacturing. If manufactured separately, the different lattice structures can be connected by various methods and materials, such as by welding, bonding (e.g., using adhesives) or using fasteners such as screws, and / or using integrated fastening systems, where the connection features are integrated into the lattice and / or solid structure, such as by 3-D printing. In one embodiment, the entire body support structure 32, including the base 34, seat 6 and backrest 8, can be integrally formed as a single, homogenous unit by additive manufacturing methods including, for example, 3-D printing, although the materials used for different lattice structures are different if desired.

[0114] refer to Fig.35 In one embodiment, one or more of the structural lattice structure, the compression lattice structure, and the skin lattice structure are designed by creating a two-dimensional surface map or BREP (boundary representation), which is converted into a volume model by voxelization map to configure a three-dimensional (3-D) model. A consistent voxel model is essentially a 3-D matrix, and each element of the matrix represents a voxel. In 3D printing, a voxel represents a value on a regular grid in three-dimensional space, similar to a pixel with volume. Each voxel contains volume information that defines a structure with desired properties. As described above, the lattice structure conforms to the external geometry, which can be arbitrary, such as the structural lattice structure provides bending resistance and / or tensile and compressive stiffness in different directions along the seat and backrest, and the compression lattice structure provides compression properties in different directions along the seat and backrest; the lattice structure conforms to or follows the geometry of the seat structure to ensure that the lattice structure and its resulting properties are correctly oriented throughout the body support structure. For example, a voxel model includes voxels that assume logical values, where 1 represents solid space and 0 represents empty space. In one embodiment, repeating elements can be tessellated in areas and the lattice is trimmed at the boundaries. The skin may be applied to the trimmed lattice structure, for example by integral molding or 3-D printing, to improve the integrity and appearance of the lattice structure along the outermost boundaries of the structure.

[0115] The 3-D model can be used to program a 3-D printer to perform 3-D printing or other additive manufacturing means. Thus, the designer can quickly and easily modify the 3-D model, such as by changing the size, shape, and curvature of the entire seat surface and geometric boundaries, and by modifying the lattice construction and materials to change the stiffness and weight characteristics of each structure. The entire body support structure or its components can be manufactured entirely in one location without the need for complex tooling, assembly processes, or mechanical fasteners. In addition, changes to the configuration of one or more components or the entire chair can be quickly and easily made through programmatic changes rather than through complex and expensive retooling.

[0116] It should be understood that the entire body support structure can be made without any mechanical interconnection, which is defined as two parts that can move relative to each other and connect in a locked configuration, including, for example, but not limited to, mechanical fasteners such as screws and bolts, snap-fit ​​tabs or detents, thereby eliminating various assembly steps. For example, the base, seat, and backrest can be assembled without any mechanical interconnection or fasteners, although it should be understood that other auxiliary items such as armrests, tablet work surfaces, headrests, etc. can be connected to the body support structure, whether through mechanical interconnection, welding, gluing, or integrating these functions through additive manufacturing processes.

[0117] The non-lattice structures 100, 102 may also provide locations and opportunities to manufacture separate parts or components that are subsequently joined at these locations, such as by having an insert extending from one component housed in a cavity of the other component, the two components being further connected with an adhesive or other fastening system including mechanical fasteners. Such a structure allows smaller components to be manufactured by additive manufacturing while still realizing all of its benefits, such as eliminating tools and mechanical fasteners such as screws and bolts, although such fasteners may also be used in some embodiments. Different lattice structures may also be printed separately in a green state and then the lattice structures assembled (arranged adjacent to each other or supporting each other), wherein after the entire structure / assembly is dried, it is bonded or connected to adjacent structures while the lattice structure is also set. Additionally or alternatively, the lattice or solid structure may include integrated features, such as hooks, bumps or other features, which can be engaged to secure one component or part to another.

[0118] The entire body support structure or its components can be manufactured entirely at a single manufacturing location without complex tools, assembly processes or mechanical fasteners. The manufacturing locations can be dispersed in different locations, such as the nearest point of sale or delivery point, and receive 3-D models and instructions from the remote location, such as through wireless communication.

[0119] Manipulation of body support structures

[0120] In operation, the user applies forces to the body support structure 32, such as the skin lattice structure 146, which provides flexibility and support to the user, and the skin lattice structure expands by resisting shear and transmits loads to the spaced-apart compression lattice structure beams 114. The compression lattice structure, which defines the cross members 118 located along the front of the seat, provides soft, compressible support for the user's thighs. Similarly, the compression lattice structure's uprights 116 provide soft, compressible support for the user's back, such as along the lumbar region. The user's L NLoads are transferred from the skin lattice structure 146 to the compression lattice structure 134 and then to the structural lattice structure, or directly to the underlying frames 360 , 362 .

[0121] As the user reclines in the body support structure, the flex regions 210, 212 may allow the seat and backrest to tilt backward, while the struts 86 provide the biasing force and maximum tilt / recline to the seat.

[0122] Various seat structure embodiments disclosed herein provide a soft outer peripheral edge that allows the user to support and bend the peripheral edge without encountering hard contact points. The peripheral edge is independently flexible and responsive to loads. Various lattice configurations can be adjusted to optimize and change support for various desired locations, such as but not limited to the lumbar, chest and pelvic regions of the backrest, or the thigh and buttocks regions of the seat. It should be understood that although many embodiments have been described herein for chair structures, the same embodiments are equally applicable to other body support structures, such as beds, sofas, or vehicle seat structures.

[0123] Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the present invention. Therefore, it is intended that the foregoing detailed description be regarded as illustrative rather than restrictive, and that it is the appended claims, including all equivalents thereof, that are intended to define the scope of the present invention.

Claims

1. A body support structure comprising: A structural frame structure having a first stiffness; a compression lattice construction supported by the structural lattice construction, wherein the compression lattice construction has a second stiffness less than the first stiffness, the compression lattice construction being compressible in response to a first normal force applied thereto; as well as A skin lattice structure supported by the compression lattice structure, wherein the skin lattice structure is resistant to shear deformation in response to a second normal force applied thereto, and wherein the skin lattice structure can expand in a direction perpendicular to the second normal force applied thereto in response to the second normal force applied thereto.

2. The body support structure of claim 1, wherein the compression lattice structure comprises a pair of spaced apart beams defining an opening therebetween, wherein the skin lattice structure is coupled to the compression lattice structure and spans the opening.

3. The body support structure of claim 2, wherein at least a portion of the skin lattice construction covering the opening is not supported by any other structure.

4. The body support structure of claim 2 wherein the compression lattice structure includes a cross member connecting the beams and located proximate the front of the seat portion.

5. A body support structure as described in claim 1, wherein the compressed lattice structure includes a unit matrix, the matrix including a first part having at least one layer of unit cells and a second part having multiple layers of unit cells, wherein the second part has more layers of unit cells than the first layer and includes a transition part between the first and second parts.

6. The body support structure of claim 1, wherein the compressed lattice construction includes an inner core lattice and a face lattice connected to the core lattice and defining an outermost surface of the compressed lattice construction.

7. The body support structure of claim 1, further comprising non-lattice structures between portions of the structural lattice structure such that the structural lattice structure is discontinuous.

8. The body support structure of claim 1, wherein the non-lattice structure comprises a solid or tubular structure.

9. The body support structure of claim 1, wherein the structural lattice construction defines at least a portion of a base, a seat support connected to the base, and a back frame connected to either the base or the seat support.

10. The body support structure of claim 9, wherein the base includes a pedestal having a ground engaging portion.

11. The body support structure of claim 10, further comprising a support post disposed between the base and one of the seat support or the back frame.

12. The body support structure of claim 11, wherein the support column comprises: spaced first and second ends respectively connected to the base and one of the seat support or back frame; and an intermediate compression grid structure connected to the first and second ends; wherein the first and second ends are movable between a nominal position and a compressed position, and the intermediate compression grid structure is compressible between a nominal configuration and a compressed configuration corresponding to the nominal and compressed positions; when in the compressed configuration, the intermediate compression grid structure applies a biasing force to the first and second ends.

13. The body support structure of claim 9, wherein a front portion of the seat support is pivotally connected to the base at the curved region, wherein the seat support is cantilevered rearwardly from the curved region, and wherein the back frame extends upwardly from the seat support.

14. The body support structure of claim 1, wherein the skin lattice construction comprises: a plurality of spaced apart support members defining opposing first and second surfaces, wherein adjacent support members define openings between sides of adjacent support members; a plurality of spaced-apart base members defining opposing first and second surfaces, wherein the first surface of the base members faces toward and is spaced from the second surface of the support member such that the plurality of support members and the plurality of base members define a space therebetween; wherein each base member is located below at least a portion of an opening defined by at least two adjacent forehead support members, and wherein adjacent base members define openings between sides of adjacent base members, wherein at least some of the base members are connected to the compression lattice structure; A plurality of connectors extend through the space and connect each base portion with at least two adjacent support members.

15. A body support structure as claimed in claim 14, wherein at least some of the base members have through holes that underlie at least part of the opening defined by at least two adjacent support members.

16. The body support structure of claim 1, wherein at least a portion of one of the structural lattice construction or the compressed lattice construction is discontinuous.

17. The body support structure of claim 1, wherein the structural lattice structure, the compression lattice structure, and the skin lattice structure are free of any mechanical interconnections.

18. The body support structure of claim 1, wherein at least one of the structural lattice construction, the compression lattice construction, and the skin lattice construction includes integrated kinematic properties.

19. The body support structure of claim 18, wherein the integrated kinematic features include motion limiters.

20. The body support structure of claim 18, wherein the integrated kinematic feature includes a biasing member.

21. The body support structure of claim 1, wherein the compressed lattice construction comprises thermoplastic polyurethane.

22. The body support structure of claim 1, wherein the structural frame construction comprises polypropylene.

23. A method of manufacturing the body support structure of claim 1, comprising forming the structural lattice structure, the compression lattice structure and the skin lattice structure by additive manufacturing.

24. The method of claim 23, wherein the additive manufacturing comprises 3-D printing.

25. The method of claim 24, wherein the 3-D printing comprises integrally forming the structural lattice structure, the compression lattice structure, and the skin lattice structure in a single 3-D printing operation.

26. The method of claim 24, further comprising defining one or more of a structural lattice configuration, a compression lattice configuration, and a skin lattice configuration by creating a two-dimensional surface map and voxelizing the map to configure a three-dimensional model operable to program a 3-D printer to perform 3-D printing.

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