User support assembly for a vehicle

Abstract

The present disclosure provides a user support assembly for a vehicle. A user support includes at least one cushioning component having a porous grid matrix formed by an additive process. The porous grid substrate may include a plurality of integrally formed tubular portions. Sound channels may be integrally formed in the porous grid matrix to carry sound from a remote source to openings in the user support.

Description

Technical Field

[0001] The present invention generally relates to a user support assembly for a vehicle, and more particularly to a user support assembly having one or more cushioning members having a porous grid matrix. Background Art

[0002] Various types of user supports have been developed to support the operator and / or passengers of a motor vehicle during operation. Summary of the Invention

[0003] One aspect of the present disclosure is a user support assembly including a frame having a lower portion with upper and lower sides and a back portion having front and rear sides. A cushioning member is disposed on the frame. The cushioning member has an outer side that elastically deforms when a user applies a force to the outer side. The cushioning member includes a unitary integral porous grid matrix formed by a plurality of interconnected links that define a plurality of cells, the plurality of cells being disposed through the porous grid matrix and interconnected with each other to form a plurality of cell layers. At least a first cell in a first cell layer includes a curved upper link having a concave lower surface, a convex upper surface, and opposite ends of the curved upper link integrally joined to a pair of lower cells. The curved upper link of the pair of lower cells has a convex upper surface that defines a lower surface of the first cell. The pair of lower cells is disposed in a lower cell layer below the first row of cells. An upper cell layer is disposed above the first cell layer and includes a pair of upper cells. Each upper cell has a curved upper link, and ends of the curved upper link are integrally joined to the curved upper link of the first cell.

[0004] · The upper link of the first cell may include a horizontally extending upper wall of the first cell.

[0005] · The upper wall of the first cell may include a plurality of openings therethrough.

[0006] · The upper links of the pair of lower cells may include horizontally extending upper walls of the pair of lower cells, and the upper links of the pair of upper cells may include horizontally extending upper walls of the pair of upper cells.

[0007] · The cells of the first cell layer, the upper cell layer, and the lower cell layer may include elongated tubular structures.

[0008] · The walls of the cells of the first cell layer, the upper cell layer, and the lower cell layer may have a substantially uniform thickness.

[0009] · The units of the first unit layer, the upper unit layer, and the lower unit layer may have the same size and shape.

[0010] · At least some of the units of the first unit layer, the upper unit layer, and the lower unit layer may have different elasticity from other units of the first unit layer, the upper unit layer, and the lower unit layer, whereby at least a first part of the outer side surface of the cushioning member may have greater elasticity than a second part of the outer side surface of the cushioning member.

[0011] · The cushioning member may be positioned on the back portion of the frame, and the outer side surface of the cushioning member may face the forward direction. The cushioning member may include at least one tubular sound channel integrally formed with the porous grid matrix. The at least one tubular sound channel may have an upper opening on the outer side surface of the cushioning member, a lower opening on the lower portion of the cushioning member, and a central portion extending through the porous grid matrix between the upper opening and the lower opening, whereby sound entering the lower opening is transmitted through the tubular sound channel and exits at the upper opening.

[0012] Another aspect of the present disclosure is a user support assembly that includes a frame having a lower portion and an upright back portion. The user support assembly also includes a cushioning member disposed on the frame. The cushioning member has an elastic homogeneous one-piece integral porous grid matrix including a plurality of elongated units. At least four of the elongated units may be disposed around an integral joint portion. Each of the elongated units includes an upper sidewall and a first lower sidewall and a second lower sidewall. The upper sidewall and the first lower sidewall and the second lower sidewall have an upwardly facing convex surface and a downwardly facing lower surface. The elongated unit includes an upper tubular portion and a lower tubular portion that are vertically aligned, and a first tubular portion and a second tubular portion that are horizontally aligned. The first lower sidewall and the second lower sidewall of the upper tubular portion include portions of the upper sidewalls of the horizontally aligned first tubular portion and the second tubular portion. The joint portion is formed at the intersection of the edges of the upper sidewalls of the horizontally aligned first tubular portion and the second tubular portion and the central portion of the upper sidewall of the lower tubular portion. The first and second opposite edge portions of the upper sidewall of the upper tubular portion intersect the upper sidewalls of the horizontally aligned first and second tubular portions, respectively, whereby when a force is applied to the cushioning member, the upper sidewalls of at least four tubular portions and the first and second lower sidewalls elastically deform.

[0013] · The at least four tubular portions may optionally have the same cross-sectional shape.

[0014] · The upper sidewalls of the at least four tubular portions may optionally have the same thickness.

[0015] · The first and second lower sidewalls of the at least four tubular portions may optionally have the same thickness.

[0016] · The upwardly convex surfaces of the upper sidewalls of at least four tubular portions may be cylindrical.

[0017] · The upper sidewalls of at least two of the tubular portions may have different thicknesses.

[0018] · The tubular portions may be parallel to each other.

[0019] · The upper sidewall of at least one tubular portion may include one or more openings therethrough.

[0020] · The cushioning member may optionally include an upper web on the upper side surface of the cushioning member, wherein the upper web is integrally formed with the upper sidewall of the horizontally adjacent tubular portion, thereby forming an upper tubular portion layer of the cushioning member.

[0021] · Each tubular portion may have a centerline, and the upper web may include a plurality of grooves extending parallel to the upper tubular portion layer. The grooves may be located intermediate the centerlines of the adjacent tubular portions of the upper tubular portion layer.

[0022] · The cushioning member may optionally include a lower web on the lower side surface of the cushioning member, wherein the lower web is integrally formed with the lower edge portion of the upper sidewall of the horizontally adjacent lower tubular portion of the lower tubular portion layer of the cushioning member, whereby the tubular portions of the lower tubular portion layer have a semi-circular cross-sectional shape.

[0023] · The single-piece integral porous grid substrate is optionally homogeneous.

[0024] Another aspect of the present disclosure is a user support assembly that includes a frame and a cushioning member supported by the frame. The cushioning member has an outer side surface and includes a porous grid substrate formed by an additive process. The cushioning member may include at least one tubular sound channel integrally formed with the porous grid substrate. The at least one tubular sound channel may have an upper opening on the outer side surface of the cushioning member, a lower opening on the lower portion of the cushioning member, and a central portion that extends between the upper opening and the lower opening through the porous grid substrate, whereby sound entering the lower opening is transmitted through the tubular sound channel and exits at the upper opening.

[0025] · The tubular sound channel and the porous grid substrate may include a homogeneous single-piece polymer structure.

[0026] · The porous grid substrate may include a plurality of horizontally extending tubular portions.

[0027] Those skilled in the art will further understand and appreciate these and other features, advantages, and objectives of the present disclosure by reference to the following specification, claims, and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In the drawings:

[0029] Figure 1 is a perspective view of a user support member according to one aspect of the present disclosure;

[0030] Figure 2 is a perspective view of a user support member according to another aspect of the present disclosure;

[0031] Figure 3 is Figure 1 an exploded perspective view of the user support member;

[0032] Figure 4 is a partial schematic cross-sectional view of the user support member taken along line IV-IV; Figure 1 of the user support member;

[0033] Figure 5 is a perspective view of a buffer member according to one aspect of the present disclosure;

[0034] Figure 5A is a perspective view of a buffer member according to another aspect of the present disclosure;

[0035] Figure 6 is a cross-sectional view of the buffer member taken along line VI-VI; Figure 5 of the buffer member;

[0036] Figure 6A is Figure 6 an enlarged partial view of the substrate;

[0037] Figure 7 is a graph showing the force-displacement curves of various grid configurations;

[0038] Figure 7A is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0039] Figure 7B is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0040] Figure 7C is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0041] Figure 7D is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0042] Figure 7E is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0043] Figure 7Fis a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0044] Figure 7G is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0045] Figure 7H is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0046] Figure 7I is a partial schematic perspective view of a grid structure according to one aspect of the present disclosure;

[0047] Figure 8 is a schematic view of a vehicle including a user support according to another aspect of the present disclosure; and

[0048] Figure 9 is Figure 8 a partial enlarged view of a part of the user support. DETAILED DESCRIPTION

[0049] This application is related to U.S. Patent Application No. 18 / 541,404 (Attorney Docket No. 84805763) titled "VEHICLE USER SUPPORT INCLUDING UPPERHOOD MODULE" filed on the same day as this application, and U.S. Patent Application No. 18 / 541,851 (Attorney Docket No. 84805805) titled "VEHICLE USER SUPPORT INCLUDING FLEXIBLE LIGHTING FEATURES" filed on the same day as this application, the entire contents of which are incorporated herein by reference.

[0050] Reference will now be made in detail to the preferred embodiments of the present disclosure, which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. In the drawings, the structural elements depicted are not drawn to scale, and for purposes of emphasis and understanding, certain components are enlarged relative to other components.

[0051] As used herein, the term "and / or" when used in connection with two or more listed items means that any one of the listed items can be taken alone, or any combination of two or more of the listed items can be taken. For example, if a composition is described as containing components A, B, and / or C, the composition can contain: only A; only B; only C; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0052] In this document, relational terms such as first and second, top and bottom, etc. are used solely to distinguish one entity or action from another entity or action, and do not necessarily require or imply any actual such relationship or order between such entities or actions. The terms "comprising," "including," or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element preceded by "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0053] As used herein, the term "about" means that a quantity, dimension, formulation, parameter, and other quantities and characteristics are not exact and need not be exact, but may be approximate and / or larger or smaller as required: reflecting tolerances, conversion factors, rounding, measurement errors, etc. and other factors known to those skilled in the art. When the term "about" is used to describe an endpoint of a value or range, the present disclosure should be understood to include the specific value or the recited endpoint. Whether or not the numerical value or the endpoint of the range in the present specification recites "about," the endpoint of the numerical value or the range is intended to include two embodiments: one modified by "about" and one not modified by "about." It should also be understood that each endpoint of the range is significant both in relation to the other endpoint and independently of the other endpoint.

[0054] As used herein, the terms "substantially," "essentially," and variations thereof are intended to indicate that the described feature is equal to or approximately equal to a value or description. For example, a "substantially planar" surface is intended to indicate a planar or approximately planar surface. Additionally, "essentially" is intended to indicate that two values are equal or approximately equal. In some embodiments, "essentially" may indicate that the values are within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0055] Unless expressly indicated to the contrary, as used herein, the terms "the," "a," or "an" mean "at least one" and should not be limited to "only one." Thus, for example, unless the context clearly indicates otherwise, a reference to "a component" includes embodiments having two or more such components.

[0056] For the purposes described herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall be related to Figure 1It is related to the concept of medium orientation. However, it should be understood that unless explicitly specified to the contrary, the described concept can assume various alternative orientations. It should also be understood that the specific devices and processes shown in the drawings and described in the following specification are merely exemplary embodiments of the inventive concept defined in the appended claims. Therefore, unless the claims otherwise explicitly state, the specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered restrictive.

[0057] Reference Figure 1 , a seat or user support 1 according to one aspect of the present disclosure includes a frame 2 (see also Figure 4 ), the frame having a lower portion 3 and an upright back portion 4. A support assembly 5 may include an attachment structure 6 configured to secure the user support 1 to the floor pan 7 of a motor vehicle 8 (see also Figure 4 ). One or more cushioning members 10, 12 may be provided on the frame 2. Reference Figure 4 , the cushioning members 10, 12 include a one-piece integral porous grid matrix 14, which can be formed by an additive process, whereby the one-piece integral porous grid matrix 14 is homogeneous. As discussed below, at least a portion of the porous grid matrix 14 may be elastic to provide cushioning for the user. The user support 1 optionally includes a foam 16 that may form an opening or channel 17, whereby the grid matrix 14 can be at least partially surrounded by the foam 16. However, the foam 16 is not required, and the porous grid matrix 14 may include only the elastic user support surface.

[0058] A seat or user support 1A ( Figure 2 ) according to another aspect of the present disclosure may include a frame 2A and cushioning members 10A and 12A having a one-piece integral porous grid matrix 14. The user support 1 ( Figure 1 ) includes an upper module 18 and an upper cushion 19, while the user support 1A ( Figure 2 ) includes an upper cushion 19A but does not include an upper module. It should be understood that the present disclosure is not limited to the Figure 1 and Figure 2 arrangements.

[0059] Further reference Figure 5 , Figure 6 and Figure 6A , the cushioning member 10 may include a plurality of cells 22 having curved links, which may optionally be in the form of sidewalls, whereby the cells 22 may be tubular. As discussed below, the cushioning member 10A ( Figure 5A ) is similar to the cushioning member 10 ( Figure 5), and further includes an optional opening 46 to provide increased flexibility when required for a particular application. The cushioning members 10 and 10A include a one-piece integral structure that can be formed from a polymer or other material by an additive process (“3D printing”), whereby the one-piece integral porous grid matrix 14 includes a homogeneous structure. Refer to Figure 6 , each tubular portion 22 can have an upper curved link such as side wall 24, and a first lower curved link and a second lower curved link such as side walls 25 and 26. The upper side wall 24 has an upwardly facing convex surface 27, and the first lower side wall 25 and the second lower side wall 26 have upwardly facing convex surfaces 28 and 29, respectively. The tubular portions 22 form a plurality of layers 30A - 30E such that the upper side wall 24 of each tubular portion 22 also includes the lower side walls 25 and 26 of the tubular portions 22 in the vertically adjacent layers of the tubular portions 22.

[0060] Refer to Figure 6A , the porous grid matrix 14 can include four tubular portions 22A - 22D disposed around the joint 23A, wherein each of the tubular portions 22A - 22D has an upper side wall 24 and a first lower side wall 25 and a second lower side wall 26, respectively. The four tubular portions 22A - 22D include a vertically aligned upper tubular portion 22A and a lower tubular portion 22D and horizontally aligned tubular portions 22B, 22C. The joint 23A is formed at the intersection of the opposite edges 32B, 32C of the upper side walls 24B, 24C of the tubular portions 22B, 22C and the central portion 33D of the upper side wall 24D of the lower tubular portion 22D. The opposite edge portion 32A of the upper side wall 24A of the upper tubular portion 22A intersects the central portions of the upper side walls 24B, 24C of the tubular portions 22B, 22C, whereby when a force “F” is applied to the cushioning member 10, the side walls of the tubular portions 22A - 22D elastically deform. It should be understood that the tubular portions 22A - 22D represent an area of the porous grid matrix 14, and the pattern formed by the tubular portions 22A - 22D can be repeated throughout the porous grid matrix 14.

[0061] As Figure 6A shown, the side walls extending around each tubular portion 22 can have a substantially uniform thickness “T”. However, the thickness “T” of each side wall can be non-uniform, and some of the side walls can have an increased thickness relative to other side walls. Thus, the thickness of the side walls forming the grid matrix 14 can be non-uniform to provide the desired flexibility and / or regions with different flexibilities. For example, refer to Figure 5, the central portion 34 of the cushioning member 10 (defined by the dashed line 36) may include sidewalls having a different thickness from the sidewalls of the peripheral region 35, such that the central portion 34 and the peripheral portion 35 have different elasticities (rigidities) to provide different forces (e.g., pressures) under a given displacement (deformation) or different deformations under a given force (pressure). Generally, the force (pressure) per unit area on the cushioning member 10 due to contact with the user can be measured or predicted, and the stiffness of different regions of the cushioning member 10 can be adjusted to provide desired characteristics (e.g., increased comfort). Thus, different zones or regions of the cushioning member 10 can have almost any desired stiffness, and the profile of the region can have almost any shape, including curved or irregular shapes as shown by the dashed line 36A.

[0062] The cushioning member 10 may optionally include an upper web 38 on the upper side 41 of the cushioning member 10 ( Figure 5 , Figure 6 ). The upper web 38 is optional, and the entire upper surface 27 of the upper sidewall 24 of the tubular portion 22 of the top row 30A can be exposed. The web 38 may include a plurality of upwardly opening grooves 39. Alternatively, the upper web 38 may be substantially flat (without grooves 39), as shown by the dashed line 40. The upper web 38 on the upper side 41 of the cushioning member 10 may be integrally formed with the material of the grid matrix 14 by an additive process (e.g., 3D printing). The cushioning member 10 may also include a lower web 42, which is integrally formed with the grid matrix 14 on the lower side 43 of the cushioning member 10. The cushioning member 10 or 10A may optionally include one or more openings 46 (also see Figure 5A ), which extend through the upper web 38 and / or one or more upper sidewalls 24 of the grid matrix 14. Generally, the sidewalls of the grid matrix 14 may include openings 46 only in selected positions to provide increased elasticity in the regions of the selected positions. The openings 46 may be configured to provide ventilation, or reduce the stiffness in the selected regions, and / or provide other features required for a particular application.

[0063] Referring again to Figure 6 , an optional upper layer 48 may be provided on the upper side 41 of the cushioning member 10. The upper layer 48 may include, for example, fabric, foam, or other elastic materials. For example, the upper layer 48 itself may include fabric, or the upper layer 48 may include an upper fabric layer and a thin foam sheet or layer below the fabric. However, the cushioning member 10 does not necessarily include the upper layer 48, and if there is no upper layer 48, the upper surface of the grid matrix 14 is exposed.

[0064] As discussed above, the configuration of the porous grid matrix 14 of the cushioning member 10 can be varied as needed to provide a desired overall stiffness and / or specific stiffness in selected regions of the cushioning member 10. Further reference is made to Figure 7 , various materials can have force-displacement curves as shown by lines 45A - 45L. Lines 45J - 45L represent conventional foam cushions that do not include a porous grid matrix. Lines 45A - 45I respectively correspond to Figure 7A - 7I the grid cell structures 50A - 50I. One or more of the grids 50A - 50I can be utilized to form the porous grid matrix 14. It should be understood that the force curves of lines 45A - 45I can be different from the Figure 7 results shown if the materials and / or sizes of the individual links forming the grid cells 50A - 50I ( Figure 7A - 7I ) are changed. Lines 45A - 45I show that the grid structures 50A - 50I can have significantly different force-displacement characteristics. For example, the grid cell structures 50A and 50B (corresponding to lines 45A and 45B) have a substantially linear force-displacement, and both reach a force of approximately 0.4 kN before a displacement of 5 mm. As another example, the force curve 45E of the grid cell structure 50E initially slopes upward at a relatively rapid rate until approximately 5 mm, then increases at a more gradual rate until approximately 20 mm of displacement, and then line 45E increases more rapidly.

[0065] The porous grid matrix 14 can include a plurality of interconnected unit structures (e.g., one or more of the unit structures 50A - 50I) formed by an additive process. The grid matrix 14 can include different grid cells in different regions to provide different elasticities. For example, the porous grid matrix 14 can include the grid cell 45A in regions where increased stiffness is required, and can include the grid cell 45D in regions where reduced stiffness is required. Also, the dimensions of the links of the grid cells 50A - 50I can be increased or decreased to adjust the stiffness. For example, the diameter of one or more links of the grid cell 50C can be increased or decreased as needed. As discussed, the polymeric material of the units used to form the porous grid matrix 14 can also be selected to provide a desired stiffness.

[0066] Generally, the cushioning member 10 can include a grid matrix 14 that includes, according to the needs of a particular application, one or more of the grid cell structures as shown in Figure 5 , Figure 6A and Figure 7A - 7I . For example, if a particular application requires a relatively rigid grid, those corresponding to lines 45A and 45B ( Figure 7) the grid cell structures 50A or 50B. However, if a reduced force versus displacement is desired, one of the other grid structures can be selected (e.g., grids 50C or 50D corresponding to lines 45C and 45D). Moreover, the grid matrix 14 can include more than one grid structure to provide different elasticities in different regions of the cushioning member 10.

[0067] As described above, the grid matrix 14 can be formed using an additive manufacturing process (3D printing). The grid matrix 14 can be made of almost any suitable material. The process can include multi-jet fusion (MJF), fused deposition modeling (FDM), selective laser sintering (SLS) of polymers, or other suitable processes. The material for forming the grid matrix 14 is preferably a polymeric material such as thermoplastic polyurethane (TPU) or other suitable materials.

[0068] Further referring Figure 8 and Figure 9 , the user support 1 can include a sound tube or audio channel 70 that carries sound from one or more sound sources 72A and 72B. The channel 70 can include one or more segments in the form of tubes 73A and 73B that are connected at a junction 74 to an upwardly extending portion 75. The upper portion 76 of the channel 70 ( Figure 9 ) can include a tubular structure formed by a material layer 77. The layer 77 can be integrally formed with the grid 56 such that sound 78 travels through the upper portion 76 of the channel 70 and exits at an upper opening 79. The opening 79 can be formed and positioned in a similar manner and at a location similar to the opening 64 ( Figure 3 ) for the speaker 66. The source 72A and / or 72B can include almost any sound source as described in U.S. Patent No. 11,280,303, the entire content of which is incorporated herein by reference. For example, if the vehicle 2 has a front-engine configuration, the source 72A can include the intake of an internal combustion engine located under the hood of the vehicle 2, and the source 72B can include the exhaust system of the internal combustion engine of the vehicle 2. If the vehicle 2 has a rear-engine or mid-engine configuration, the source 72A can include the intake of the internal combustion engine, and the source 72A can be located in the rear portion of the vehicle 2.

[0069] It should be understood that changes and modifications can be made to the structures mentioned above without departing from the spirit of the present disclosure, and further it should be understood that such spirit is intended to be covered by these claims unless the appended claims state otherwise expressly by their language.

[0070] According to the present invention, a user support assembly is provided, the user support assembly having: a frame having a lower portion with an upper side and a lower side, and a back portion having a front side and a rear side; and a cushioning member disposed on the frame, the cushioning member having an outer side that elastically deforms when a user applies a force to the outer side, the cushioning member including a one-piece integral porous grid matrix formed by a plurality of interconnected curved linkages, the plurality of interconnected curved linkages defining a plurality of cells disposed through the porous grid matrix, wherein the curved linkages form a plurality of cell layers, wherein the curved linkages have a concave lower surface and a convex upper surface, wherein opposite ends of the curved linkages are integrally joined to curved linkages of adjacent cells, and wherein opposite ends of the curved linkages of each layer are also integrally joined to central portions of curved linkages of cells in an adjacent cell layer below each cell layer.

[0071] According to one embodiment, the curved linkages of the cells include horizontally extending walls.

[0072] According to one embodiment, the walls of at least one cell include a plurality of openings therethrough.

[0073] According to one embodiment, the curved linkages of the cells in vertically adjacent upper and lower cell layers include horizontally extending upper and lower walls of the cells in the lower and upper cell layers, respectively.

[0074] According to one embodiment, the cells include elongated tubular structures.

[0075] According to one embodiment, the walls of the cells have a substantially uniform thickness.

[0076] According to one embodiment, the cells of each cell layer have the same size and shape.

[0077] According to one embodiment, the cells of a first cell layer, the cells of cell layers above the first cell layer, and the cells of cell layers below the first cell layer have an elasticity different from that of other cells, whereby at least a first portion of the outer side of the cushioning member has a greater elasticity than a second portion of the outer side of the cushioning member.

[0078] According to one embodiment, the cushioning member is positioned on the back portion of the frame, and the outer side surface of the cushioning member faces the forward direction; the cushioning member includes at least one tubular sound channel integrally formed with the porous grid matrix; the at least one tubular sound channel has an upper opening on the outer side surface of the cushioning member, a lower opening on the lower portion of the cushioning member, and extends through the central portion of the porous grid matrix between the upper opening and the lower opening, whereby sound entering the lower opening is transmitted through the tubular sound channel and exits at the upper opening.

[0079] According to the present invention, there is provided a user support assembly having: a frame having a horizontal lower portion and an upright back portion; and a cushioning member disposed on the frame, the cushioning member having a homogeneous one-piece integral porous grid matrix, the homogeneous one-piece integral porous grid matrix including a plurality of tubular portions, including a region where four tubular portions are disposed around an integral joint, wherein the four tubular portions include a vertically aligned upper tubular portion and a lower tubular portion and a horizontally aligned first tubular portion and a second tubular portion, each of the four tubular portions having an upper side wall having first and second opposite edge portions and a first lower side wall and a second lower side wall, each upper side wall and each first lower side wall and second lower side wall having an upwardly facing convex surface and a downwardly facing lower surface, and wherein the first lower side wall and the second lower side wall of the upper tubular portion include the first portion and the second portion of the upper side wall of the horizontally aligned first tubular portion and second tubular portion, and wherein the integral joint is formed at the intersection of the edge portions of the upper side walls of the horizontally aligned first tubular portion and second tubular portion and the central portion of the upper side wall of the lower tubular portion, and wherein the first and second opposite edge portions of the upper side wall of the upper tubular portion intersect the central portions of the upper side walls of the horizontally aligned first tubular portion and second tubular portion respectively, whereby when a force is applied to the cushioning member, the side walls of the four tubular portions elastically deform.

[0080] According to one embodiment, the four tubular portions have the same cross-sectional shape.

[0081] According to one embodiment, the upper side walls of the four tubular portions have the same thickness.

[0082] According to one embodiment, the first lower side wall and the second lower side wall of each of the four tubular portions have the same thickness.

[0083] According to one embodiment, the upwardly convex surface of the upper sidewall of each of the four tubular portions is cylindrical; the upper sidewalls of at least two of the tubular portions have different thicknesses; and the tubular portions are parallel to each other.

[0084] According to one embodiment, the upper sidewall of at least one of the tubular portions includes a plurality of openings therethrough.

[0085] According to one embodiment, the cushioning member includes an upper web on the upper side of the cushioning member, and wherein the upper web is integrally formed with the upper sidewall of the horizontally adjacent tubular portion.

[0086] According to one embodiment, each tubular portion has a centerline; the porous grid substrate includes an upper layer of tubular portions and a lower layer of tubular portions; the upper web includes a plurality of upwardly opening grooves extending parallel to the upper layer of tubular portions, wherein the grooves are located between the centerlines of the adjacent tubular portions of the upper tubular portion layer; and the cushioning member includes a lower web on the lower side of the cushioning member, wherein the lower web is integrally formed with the tubular portions of the lower layer of tubular portions.

[0087] According to the present invention, there is provided a user support assembly having: a frame; and a cushioning member supported by the frame, the cushioning member having an outer side and including a porous grid substrate formed by an additive process; wherein the cushioning member includes at least one tubular sound channel integrally formed with the porous grid substrate, the at least one tubular sound channel having an upper opening on the outer side of the cushioning member, a lower opening on the lower portion of the cushioning member, and a central portion extending through the porous grid substrate between the upper opening and the lower opening, whereby sound entering the lower opening is transmitted through the tubular sound channel and exits at the upper opening.

[0088] According to one embodiment, the tubular sound channel and the porous grid substrate comprise a homogeneous one-piece polymer structure.

[0089] According to one embodiment, the porous grid substrate includes a plurality of horizontally extending tubular portions.

Claims

1. A user support component, comprising: a frame having a lower portion having an upper side and a lower side, and a back portion having a front side and a rear side; as well as A buffer component is arranged on the frame, the buffer component has an outer side, and when a user applies force to the outer side, the outer side is elastically deformed, the buffer component includes a one-piece integral porous grid matrix formed by a plurality of interconnected links, the plurality of interconnected links define a plurality of units arranged throughout the porous grid matrix, wherein the links form a plurality of unit layers, wherein the opposite ends of the links are integrally joined to the bent links of adjacent units, and wherein the opposite ends of the links of each layer are also integrally joined to the links of the units in the adjacent unit layer.

2. A user support assembly as claimed in claim 1, wherein: The link includes a curved link having a concave lower surface and a convex upper surface.

3. A user support assembly as claimed in claim 1 or claim 2, wherein: The opposite ends of the links are joined to the central portion of the links of the cells below each cell layer.

4. A user support assembly as claimed in any one of claims 1 to 3, wherein: The links of the units include horizontally extending walls.

5. A user support assembly as claimed in any one of claims 1 to 4, wherein: The wall of at least one of the cells includes a plurality of openings therethrough.

6. A user support assembly as claimed in any one of claims 1 to 5, wherein: The links of the cells in vertically adjacent upper and lower cell layers include horizontally extending upper and lower walls of the cells in the lower and upper cell layers, respectively.

7. A user support assembly as claimed in any one of claims 1 to 6, wherein: The unit comprises an elongated tubular structure.

8. A user support assembly as claimed in any one of claims 1 to 7, wherein: The walls of the cells have a substantially uniform thickness.

9. A user support assembly as claimed in any one of claims 1 to 8, wherein: The cells of each cell layer have the same size and shape.

10. A user support assembly as claimed in any one of claims 1 to 9, wherein: The cells of the first cell layer, the cells of the cell layer above the first cell layer, and the cells of the cell layer below the first cell layer have elasticity different from that of other cells, whereby at least a first portion of the outer side surface of the buffer component has greater elasticity than a second portion of the outer side surface of the buffer component.

11. A user support assembly as claimed in any one of claims 1 to 10, wherein: The cushioning component is positioned on the back portion of the frame, and the outer side of the cushioning component faces in a forward direction; The cushioning component includes at least one tubular sound passage formed integrally with the porous grid matrix; The at least one tubular sound channel has an upper opening on the outer side of the cushioning component, a lower opening on the lower portion of the cushioning component, and a central portion extending through the porous grid matrix between the upper opening and the lower opening, whereby sound entering the lower opening is transmitted through the tubular sound channel and exits at the upper opening.

12. A user support component comprising: frame; as well as a cushioning component supported by the frame, the cushioning component having an outer side and including a porous grid matrix formed by an additive process; The buffer component includes at least one tubular sound channel formed integrally with the porous grid matrix, and the at least one tubular sound channel has an upper opening on the outer side of the buffer component, a lower opening on the lower portion of the buffer component, and a central portion extending through the porous grid matrix between the upper opening and the lower opening, whereby sound entering the lower opening is transmitted through the tubular sound channel and exits at the upper opening.

13. The user support assembly of claim 12, wherein: The tubular sound passage and the porous grid matrix comprise a homogeneous, one-piece polymer structure.

14. A user support assembly as claimed in claim 12 or claim 13, wherein: The porous grid matrix includes a plurality of horizontally extending tubular sections.

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