Vehicle user support including upper cover module

Abstract

The present disclosure provides a vehicle user support including an upper cover module. A user support includes a cover structure supported by a back frame structure of the user support. The cap structure may include a one-piece homogeneous polymer structure formed by an additive process. The cover structure may include a solid structure and at least one porous grid matrix integrally formed with the solid structure.

Description

Technical Field

[0001] The present disclosure generally relates to a user support for a vehicle, and more particularly to a support assembly having an upper cover module, which may include one or more components having a porous grid substrate. Background Art

[0002] Various user supports for vehicles have been developed. Such supports can be configured to support a user and / or a passenger within a vehicle during operation of the vehicle. Summary of the Invention

[0003] One aspect of the present disclosure is a user support for a vehicle. The user support includes a frame having a lower portion and a back portion extending upward from the lower portion. The user support further includes a lower cushion fixed to the lower portion of the frame. The lower cushion has an upward-facing surface. The user support includes a back cushion fixed to the back portion of the frame. The back cushion has a forward-facing surface and an upper edge. The user support further includes a one-piece polymer cover structure having: a base fixed to a back frame structure; and an upper cover structure extending upward above the upper edge of the upper back frame structure. The one-piece polymer cover structure may include an integral porous grid substrate extending across a gap between an elongated front structure and a rear structure. The user support further includes a cushion assembly positioned above the back cushion. The cushion assembly may include a left cushion and a right cushion fixed to the one-piece polymer cover structure in a side-by-side configuration. Each cushion may have a forward-facing elastic material layer and a rear material layer. Each cushion further includes a porous grid substrate integrally formed with the forward-facing elastic material layer and the rear material layer to form a one-piece homogeneous polymer structure. The porous grid substrate is disposed between the forward-facing elastic material layer and the rear material layer. The porous grid substrate has a porous outer peripheral portion or shell extending between the forward-facing elastic material layer and the rear material layer, whereby the porous outer shell is exposed and visible.

[0004] · The elongated front structures and rear structures of each left outer structure and right outer structure may extend toward each other, whereby the size of the gap between the elongated front structure and the rear structure decreases at the upper ends of the elongated front structure and the rear structure.

[0005] · The one-piece polymer cover structure may include nylon or other suitable material and may be formed using an additive process.

[0006] · The left cushion and the right cushion may optionally include thermoplastic polyurethane.

[0007] · Each of the left cushion and the right cushion has a lower edge that is spaced from the upper edge of the upper cushion to form a horizontally extending gap.

[0008] · The upper cover structure may include an integral left outer structure and right outer structure, wherein each of the left outer structure and the right outer structure includes an elongate front structure and a rear structure extending toward each other, whereby the size of the gap between the elongate front structure and the rear structure decreases at the upper ends of the elongate front structure and the rear structure.

[0009] · The one-piece polymer cover structure may include a forwardly opening cavity formed by a cavity structure integrally formed with the upper ends of the left outer structure and the right outer structure, and the user support may include a headrest having a cushion, the headrest being disposed adjacent to the forwardly opening cavity; and a support structure interconnecting the headrest to the back portion of the frame.

[0010] · The left outer structure and the right outer structure may extend upwardly and inwardly toward each other from the base.

[0011] · The one-piece polymer cover structure may include an integral porous grid matrix extending across the gap between the elongate front structure and the rear structure, wherein the integral porous grid matrix has an exposed outer side that is visible.

[0012] · Each of the elongate front structure and the rear structure may include a porous grid matrix and an impermeable outer layer extending around and encapsulating the porous grid matrix.

[0013] · The base of the one-piece polymer cover structure may include a porous grid matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous grid matrix.

[0014] · The porous grid matrix of the base of the one-piece polymer cover structure may extend horizontally across the lower portion of the base of the one-piece polymer cover structure.

[0015] · The user support may include a sound channel having a first end configured to be operably coupled to a sound source, whereby sound enters the first end of the sound channel. The sound channel has a second end having at least one opening formed in the one-piece polymer cover structure, whereby the sound entering the first end exits the at least one opening, and wherein at least a portion of the channel includes a tube structure integrally formed with the porous grid structure of the one-piece polymer cover structure.

[0016] Another aspect of the present disclosure is an upper cover module for a user support for a vehicle. The upper cover module includes a one-piece polymeric cover structure having a base configured to be secured to a back frame structure of the user support and an upper cover structure located above the base. The one-piece polymeric cover structure includes an outer layer and a porous grid matrix integrally formed with the outer layer. The one-piece polymeric cover structure includes a homogeneous polymeric structure formed by an additive process from a first polymer having a first elasticity. The cover structure further includes at least one pad secured to the one-piece polymeric cover structure. The at least one pad has a front-facing elastic material layer, a rear material layer, and an elastic porous grid matrix integrally formed with the front-facing elastic material layer and the rear material layer, whereby the at least one pad includes a one-piece homogeneous structure and wherein the porous grid matrix is disposed between the front-facing elastic material layer and the rear material layer. The at least one pad includes a homogeneous polymeric structure formed by an additive process from a second polymer having a second elasticity, wherein the second elasticity is less than the first elasticity.

[0017] · The porous grid matrix of the at least one pad has a porous outer shell that extends between the front-facing elastic material layer and the rear material layer, whereby the porous outer shell is exposed and visible.

[0018] · The at least one pad may include a left pad and a right pad positioned side by side, and the left pad and the right pad may include thermoplastic polyurethane.

[0019] · The at least one pad may include a plurality of cavities formed in the rear material layer, and the one-piece polymeric cover structure may include a plurality of protrusions positioned in the cavities of the at least one pad.

[0020] · The base of the one-piece polymeric cover structure may include a porous grid matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous grid matrix, and the porous grid matrix of the base of the one-piece polymeric cover structure may extend horizontally across a lower portion of the base of the one-piece polymeric cover structure.

[0021] · The one-piece polymeric cover structure may include a central opening and a first side opening and a second side opening, wherein the central opening and the first side opening and the second side opening may extend in a front-to-rear direction through the one-piece polymeric cover structure above the at least one pad.

[0022] Another aspect of the present disclosure is a method of manufacturing a user support for a vehicle. The method includes providing a frame having a lower portion and an upright back portion. The method further includes forming a homogeneous, one-piece polymeric cover structure using an additive process. The additive process includes forming an outer layer of polymeric material extending around at least a portion of a porous grid substrate such that the outer layer of polymeric material is formed integrally with the porous grid substrate. The method further includes securing an elastic cushion to the front side of the one-piece polymeric cover structure.

[0023] · The elastic cushion may be formed from a material having a greater elasticity than the polymeric material of the cover structure using an additive process, and at least one cushion may include an elastic porous grid substrate.

[0024] · The method may include forming a sound tube extending upwardly through the porous grid substrate of the one-piece polymeric cover structure using an additive process, wherein the sound tube is formed integrally with the porous grid substrate and an opening is formed in the front side of the one-piece polymeric cover structure.

[0025] 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

[0026] In the drawings:

[0027] Figure 1 is a partial exploded perspective view of a user support for a vehicle according to one aspect of the present disclosure;

[0028] Figure 2 is Figure 1 a perspective view of the user support;

[0029] Figure 3 is Figure 1 and Figure 2 an exploded perspective view of the user support;

[0030] Figure 4 is Figure 1 an enlarged partial exploded perspective view of a portion of the user support;

[0031] Figure 5 is a cross-sectional view of the user support taken along line V-V; Figure 2 the user support;

[0032] Figure 6 is a cross-sectional view of the user support taken along line VI-VI; Figure 2 the user support;

[0033] Figure 7 is a cross-sectional view of the user support taken along line VII-VII; Figure 2 the user support;

[0034] Figure 8 is a schematic view of a vehicle including a user support according to another aspect of the present disclosure; and

[0035] Figure 9 is Figure 8 a partial enlarged view of a part of the user support of DETAILED DESCRIPTION

[0036] This application claims the benefit of U.S. Patent Application No. 18 / 541,739, filed on the same date herewith and entitled "A USER SUPPORT ASSEMBLY FOR VEHICLES" (Attorney Docket No. 84805943), and U.S. Patent Application No. 18 / 541,851, filed on the same date herewith and entitled "VEHICLE USER SUPPORT INCLUDING FLEXIBLE LIGHTING FEATURES" (Attorney Docket No. 84805805), the entire contents of which are incorporated herein by reference.

[0037] Reference will now be made in detail to the preferred embodiments of the present disclosure, examples of 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.

[0038] 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.

[0039] In this document, relational terms such as first and second, top and bottom, etc. are used only 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 "comprises," "comprising," or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include 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.

[0040] 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, and other factors known to those skilled in the art. When the term "about" is used to describe the endpoints 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 or range endpoints in this specification are recited with "about", the numerical or range endpoints are intended to include two embodiments: one modified by "about" and one not modified by "about". It should also be understood that each endpoint of a range is significant both in relation to and independent of the other endpoint.

[0041] As used herein, the terms "substantially", "essentially" and their variants 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 mean 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.

[0042] Unless explicitly 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, a reference to "a component" includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0043] For purposes of description herein, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", and derivatives thereof shall refer to the concepts as oriented in Figure 1 . However, it should be understood that unless explicitly specified to the contrary, the said concepts may 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 concepts defined in the appended claims. Thus, unless the claims expressly state otherwise, the specific dimensions and other physical characteristics relating to the embodiments disclosed herein should not be considered limiting.

[0044] Referring to Figures 1 to 5 , the seat or user support 1 is configured for a vehicle 2 or other suitable application. The user support 1 includes a frame 3 ( Figure 3), the frame has a lower portion 4 and a generally upright back portion 5 extending upwardly from the lower portion 4. A lower cushion 8 is fixed to the lower portion 4 of the frame 3. The lower cushion 8 includes an upward-facing surface 9. The user support 1 further includes a back cushion 10 that can be fixed to the upper portion 5 of the frame 3. The back cushion 10 has a forward-facing surface 11 and an upper edge 12.

[0045] The back portion 5 of the frame 3 may include an upper back frame structure 13 extending upwardly above the upper edge 12 of the back cushion 10. The upper back frame structure 13 includes an upper edge 14 ( Figure 3 ).

[0046] The user support 1 may further include an upper cover module formed using an additive process (e.g., 3D printing), such as a one-piece polymer cover structure 20. As discussed below, the cover structure 20 may include a porous grid matrix 56 integrally formed with a housing or outer layer 54. The outer layer 54 may include gaps or openings 16 ( Figure 2 and Figure 5 ), whereby a portion of the porous grid matrix 56 is exposed (visible). The one-piece polymer cover structure 20 includes a base 22 that is fixed to the upper back frame structure 13; and an upper cover structure 24 that extends upwardly above the upper edge 14 of the upper back frame structure 13. The one-piece polymer cover structure 20 may include an integrally formed recess 42 ( Figure 5 ), which receives the upper back frame structure 13 to fix the one-piece polymer cover structure 20 to the frame 3. Mechanical fasteners or the like may be used to fix the one-piece polymer cover structure 20 to the back frame 5. The upper cover structure 24 may have a generally inverted V-shape formed by a left outer structure 26A and a right outer structure 26B, respectively. The left outer structure 26A and the right outer structure 26B extend upwardly and inwardly toward each other from the base 22. Each of the left outer structure 26A and the right outer structure 26B may include an elongate front structure 28A and a rear structure 28B spaced apart to form a gap 30. The one-piece polymer cover structure 20 includes at least one integral porous grid matrix 32 extending across the gap 30 between the elongate front structure 28A and the rear structure 28B (also see Figure 7 ). Optionally, a pair of integral porous grid matrices 32A, 32B ( Figure 7 ) may extend between the elongate front structure 28A and the rear structure 28B. The one-piece polymer cover structure 20 further includes a forward-opening recess 34 formed by a recess structure 35, which is integrally formed with the upper ends 36A and 36B of the left outer structure 26A and the right outer structure 26B.

[0047] The user support 1 further includes a headrest 38 having a cushion 40 (e.g., foam). The headrest 38 is disposed adjacent to the forwardly opening cavity 34. The headrest 38 includes one or more support structures 41( Figure 3 ) interconnected with the back portion 5 of the frame 3. The cushion 40 may optionally include an elastic porous grid structure having an optional elastic outer layer integrally formed with the elastic porous grid structure.

[0048] The user support frame 1 may further include an upper cushion assembly 44, the upper cushion assembly including a left cushion 44A and a right cushion 44B respectively fixed to a one-piece polymer cover structure 20 in a side-by-side configuration. Each cushion 44A, 44B includes a forward-facing elastic material layer 46 (see also Figure 5 ), a rear material layer 48, and a porous grid matrix 50 disposed between the elastic layer 46 and the material layer 48 using an additive process (e.g., 3D printing) to form a one-piece integral homogeneous structure. The porous grid matrix 50 is preferably elastic and integrally formed with the elastic layer 46 and the material layer 48. The porous grid matrix 50 has a porous outer shell 52 extending between the elastic layer 46 and the material layer 48 such that the porous outer shell 52 is exposed and visible. The outer shell 52 may include links of the porous grid matrix generally extending parallel to the outermost surface of the porous grid matrix 50.

[0049] The cushions 44A and 44B may be formed of an elastomeric thermoplastic polyurethane (TPU) material using a multi-jet fusion (MJF) additive manufacturing process. The thicknesses of the layers 46 and 48 and the configuration of the porous grid matrix 50 may be selected to provide a desired level of cushioning (elasticity) in the upper back region of the user. The cushions 44A and 44B may optionally be configured to have greater elasticity than the cover structure 20.

[0050] The cushions 44A and 44B may be respectively formed with cavity halves 58A and 58B that form a cavity 58( Figure 5 ), whereby a badge 60 may be positioned in the cavity 58. Generally, the cavity halves 58A and 58B may be integrally formed in the front layer 46 of the cushions 44A and 44B respectively.

[0051] Refer to Figure 3 and Figure 4 , the base 22 of the cover 20 may include a plurality of forwardly extending protrusions 66 that are closely received in cavities 63 of the cushions 44A and 44B to thereby position and secure the cushions to the cover 20. The cushions 44A and 44B may be further secured to the cover 20 using mechanical fasteners (e.g., integrally formed snap connectors), threaded fasteners, adhesives, or other suitable arrangements. Thus, the protrusions 66 and the cavities 63 are merely examples of suitable connection arrangements.

[0052] The cover 20 may include a central opening 17 and side openings 18A and 18B through the cover 20, and the elongated front structure 28A and rear structure 28B may optionally include a forward-facing opening 64 for receiving the audio speaker 66. The cover 68 may be fixed to the cover 20 above the speaker 66. The cover 68 may have a porous layer 69 that allows sound from the speaker 66 to pass through the porous layer 69. The cover 68 may be formed by an additive process and may include, for example, a TPU rubber formed by a multi-jet fusion (MJF) process or a nylon formed by a selective laser sintering (SLS) process.

[0053] Further reference Figures 5 to 7 The one-piece polymer cover structure 20 may include an outer skin or layer 54 and an integrally formed porous grid matrix 56. The one-piece polymer cover structure 20 may be manufactured using an additive process, whereby the outer layer 54 and the porous grid matrix 56 are integrally formed, such that the one-piece polymer cover structure 20 includes an integral homogeneous structure. In a preferred embodiment, the one-piece polymer cover structure 20 is manufactured using a selective laser sintering (SLS) with a nylon polymer material. The thickness and shape of the skin or layer 54 and the configuration and thickness of the porous grid matrix 56 may vary as needed to provide the desired stiffness and / or other overall structural characteristics of the one-piece polymer cover structure 20. The outer layer 54 may be substantially continuous and impermeable (except, for example, at the gaps 16), such that the porous grid matrix 56 is disposed within an integral cavity or space inside the outer layer 54. It should be understood that the porous grid matrix 56 may extend through the entire space or only a portion of the space inside the outer layer 54. For example, the outer layer 54 may provide sufficient strength and / or stiffness in some regions such that the porous grid matrix 56 is not required in these regions of the cover structure 20.

[0054] Reference Figure 5 and Figure 6 The base 22 of the cover structure 20 may include an integral inner layer or inner wall 54A that engages the upper back frame structure to support the cover structure 20 on the frame 3. The cover structure 20 may also be fixed to the frame 3 using mechanical fasteners or the like (not shown).

[0055] Reference Figure 7, the elongated front structure 28A and rear structure 28B may include a porous grid substrate 56 and an integrally formed outer layer 54 that extends around and encapsulates the porous grid substrate 56. As discussed above, the cover structure 20 may optionally include at least some internal spaces or cavities that do not include the porous grid substrate 56. For example, all or part of the space inside the outer layer 54 of the front structure 28A and / or rear structure 28B may optionally include a space without an internal structure (such as the porous grid substrate 56).

[0056] Further reference Figure 8 and Figure 9 , the user support 1 may include a sound enhancement system 80, the sound enhancement system including an audio (sound) channel 70 operably coupled to one or more sound sources 72A and 72B. The channel 70 may include one or more segments in the form of tubes 73A and 73B, the tubes being connected at a junction 74 to an upwardly extending portion 75. The upper portion 76 of the channel 70 ( Figure 9 ) includes a layer of material 77 in the form of a tube structure, the layer of material being integrally formed with the grid 56, whereby sound 78 travels through the upper portion 76 of the channel 70 and exits at the upper opening 79. The user support 1 may include two or more openings 79, the two or more openings being operably (fluidly) connected to separate branches of a single channel 70, wherein the branches extend from a "Y" - shaped junction in the channel 70. Alternatively, two or more openings 79 may be operably connected to two or more channels 70. The openings 79 may be formed and arranged in a similar manner and at a similar location to the opening 64 ( Figure 3 ) for the speaker 66, and a porous cover or grille 82 may be positioned above the openings 79.

[0057] The audio channel 70 is preferably a continuous channel that allows sound from one or more sources 72A, 72B, etc. to enter the first end of the tubes 73A and / or 73B and travel through the channel 70 to one or more openings 79 and exit the audio channel 70 adjacent the user. Examples of the sound sources 72A and 72B include engine noise or other desired noises as disclosed in U.S. Patent No. 11,280,303, the entire content of which is incorporated herein by reference. For example, the source 72A may be located under the hood of the vehicle 2 and may include an intake system of an internal combustion system, and the source 72B may include an exhaust system of an internal combustion engine. Generally, a single source 72A or 72B may be utilized. It should be understood that Figure 8 the channel 70 as well as the sound sources 72A and 72B are schematic in nature, and the channel 70 may have various configurations, and the sound sources 72A, 72B, etc. may include a wide variety of sound sources.

[0058] It should be understood that the foregoing structure can be changed and modified without departing from the concept of the present disclosure, and it should also be understood that such concepts are intended to be covered by these claims unless the appended claims clearly state otherwise by their language.

[0059] According to the present invention, there is provided a user support for a vehicle, the user support having: a frame having a lower portion and a back portion extending upwardly from the lower portion, wherein the back portion of the frame includes an upper back frame structure having an upper edge; a lower cushion fixed to the lower portion of the frame, the lower cushion having an upward-facing surface; a back cushion fixed to the back portion of the frame, the back cushion having a forward-facing surface and an upper edge; a one-piece polymer cover structure having a base fixed to the upper back frame structure and an upper cover structure extending upwardly above the upper edge of the upper back frame structure; and an upper cushion assembly fixed to the one-piece polymer cover structure, whereby the upper cushion assembly is positioned above the upper edge of the back cushion, the upper cushion assembly including at least one cushion having a forward-facing elastic material layer, a rear material layer, and an elastic porous grid matrix integrally formed with the forward-facing elastic material layer and the rear material layer to form a one-piece homogeneous polymer structure, wherein the porous grid matrix is disposed between the forward-facing elastic material layer and the rear material layer, the elastic porous grid matrix having an integral porous outer shell extending between the forward-facing elastic material layer and the rear material layer, whereby the porous outer shell is exposed and visible.

[0060] According to one embodiment: the one-piece polymer cover structure is formed from nylon using an additive process, whereby the one-piece polymer cover structure is homogeneous.

[0061] According to one embodiment: the at least one cushion includes a left cushion and a right cushion arranged in a side-by-side configuration, wherein the left cushion and the right cushion are formed from thermoplastic polyurethane using an additive process.

[0062] According to one embodiment: each of the left cushion and the right cushion has a lower edge spaced from the upper edge of the back cushion to form a horizontally extending gap.

[0063] According to one embodiment: The upper shroud structure includes an integral left outer structure and right outer structure, and the left outer structure and the right outer structure each include an elongate front structure and a rear structure extending towards each other, whereby the size of the gap between the elongate front structure and the rear structure decreases at the upper ends of the elongate front structure and the rear structure.

[0064] According to one embodiment: The one-piece polymer shroud structure includes a forwardly opening cavity formed by a cavity structure integrally formed with the upper ends of the left outer structure and the right outer structure; and includes: a headrest having a cushion, the headrest being disposed adjacent to the forwardly opening cavity; and a support structure interconnecting the headrest with the back portion of the frame.

[0065] According to one embodiment: The left outer structure and the right outer structure extend upwardly from the base and inwardly towards each other.

[0066] According to one embodiment: The one-piece polymer shroud structure includes an integral porous grid matrix extending across the gap between the elongate front structure and the rear structure, wherein the integral porous grid matrix between the elongate front structure and the rear structure has an exposed outer side that is visible.

[0067] According to one embodiment: Each of the elongate front structure and the rear structure includes a porous grid matrix and an impermeable outer layer extending around and encapsulating the porous grid matrix.

[0068] According to one embodiment: The base of the one-piece polymer shroud structure includes a porous grid matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous grid matrix, wherein the porous grid matrix of the base of the one-piece polymer shroud structure extends horizontally across the lower portion of the base of the one-piece polymer shroud structure.

[0069] According to one embodiment, the invention further features: a sound channel having a first end configured to be operably coupled to a sound source, whereby sound enters the first end of the sound channel, the sound channel having a second end having at least one opening formed in the one-piece polymer shroud structure, whereby the sound entering the first end exits through the at least one opening, and wherein at least a portion of the channel includes a tube structure integrally formed with the porous grid structure of the one-piece polymer shroud structure.

[0070] According to the present invention, there is provided an upper cover module for a user support for a vehicle, the upper cover module having: a one-piece polymer cover structure having a base configured to be fixed to a back frame structure of the user support, and an upper cover structure located above the base, the one-piece polymer cover structure including an outer layer and a porous grid matrix integrally formed with the outer layer, and wherein the one-piece polymer cover structure includes a homogeneous polymer structure formed by an additive process from a first polymer having a first elasticity; and at least one pad fixed to the one-piece polymer cover structure, the at least one pad having a forward-facing elastic material layer, a rear material layer, and an elastic porous grid matrix integrally formed with the forward-facing elastic material layer and the rear material layer, whereby the at least one pad includes a one-piece homogeneous structure, and wherein the porous grid matrix is disposed between the forward-facing elastic material layer and the rear material layer, wherein the at least one pad includes a homogeneous polymer structure formed by an additive process from a second polymer having a second elasticity, wherein the second elasticity is less than the first elasticity.

[0071] According to one embodiment: the porous grid matrix of the at least one pad has a porous outer casing that extends between the forward-facing elastic material layer and the rear material layer, whereby the porous outer casing is exposed and visible.

[0072] According to one embodiment: the at least one pad includes a left pad and a right pad positioned side by side; and the left pad and the right pad include thermoplastic polyurethane.

[0073] According to one embodiment: the at least one pad includes a plurality of cavities formed in the rear material layer; and the one-piece polymer cover structure includes a plurality of protrusions positioned in the cavities of the at least one pad.

[0074] According to one embodiment: the base of the one-piece polymer cover structure includes a porous grid matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous grid matrix, wherein the porous grid matrix of the base of the one-piece polymer cover structure extends horizontally across a lower portion of the base of the one-piece polymer cover structure.

[0075] According to one embodiment: the one-piece polymer cover structure includes a central opening and a first side opening and a second side opening, wherein the central opening and the first side opening and the second side opening extend in a front-to-rear direction above the at least one pad through the one-piece polymer cover structure.

[0076] According to the present invention, a method of manufacturing a user support for a vehicle includes: providing a frame having a lower portion and an upright back portion; forming a homogeneous one-piece polymer cover structure using an additive process, including forming an outer layer of polymer material extending around at least a portion of a porous grid substrate such that the outer layer of polymer material is integrally formed with the porous grid substrate; and securing an elastic cushion to the front side of the one-piece polymer cover structure.

[0077] In one aspect of the present invention, the method includes: forming the elastic cushion using an additive process from a material having greater elasticity than the polymer material of the cover structure, the at least one cushion including an elastic porous grid substrate.

[0078] In one aspect of the present invention, the method includes: forming a sound tube extending upward through the porous grid substrate using an additive process, wherein the sound tube is integrally formed with the porous grid substrate and forms an opening on the front side of the one-piece polymer cover structure.

Claims

1. A user support for a vehicle, the user support comprising: a frame having a lower portion and a back portion extending upwardly from the lower portion, wherein the back portion of the frame includes an upper back frame structure having an upper edge; a lower pad secured to the lower portion of the frame, the lower pad having an upwardly facing surface; a back pad secured to the back portion of the frame, the back pad having a forward facing surface and an upper edge; a one-piece polymeric hood structure having a base secured to the upper back frame structure and an upper hood structure extending upwardly over the upper edge of the upper back frame structure; as well as An upper cushion assembly, the upper cushion assembly being fixed to the one-piece polymer cover structure, whereby the upper cushion assembly is positioned above the upper edge of the back pad, the upper cushion assembly including at least one cushion, the at least one cushion having a forward-facing elastic material layer, a rear material layer and an elastic porous grid matrix, the elastic porous grid matrix being integrally formed with the forward-facing elastic material layer and the rear material layer to form a one-piece homogeneous polymer structure, wherein the porous grid matrix is ​​disposed between the forward-facing elastic material layer and the rear material layer, the elastic porous grid matrix having an integral porous outer shell extending between the forward-facing elastic material layer and the rear material layer, whereby the porous outer shell is exposed and visible.

2. A user support as claimed in claim 1, wherein: The one-piece polymer cover structure is formed from nylon using an additive process, whereby the one-piece polymer cover structure is homogeneous.

3. The user support of claim 1, wherein: The at least one cushion includes a left cushion and a right cushion disposed in a side-by-side configuration, wherein the left cushion and the right cushion are formed from thermoplastic polyurethane using an additive process.

4. A user support as claimed in claim 3, wherein: Each of the left and right cushions has a lower edge that is spaced apart from the upper edge of the back pad to form a horizontally extending gap.

5. A user support as claimed in any one of claims 1 to 4, wherein: The upper cover structure includes an integral left outer structure and a right outer structure, each of which includes a slender front structure and a rear structure extending toward each other, whereby the size of the gap between the slender front structure and the rear structure is reduced at the upper ends of the slender front structure and the rear structure.

6. A user support as claimed in claim 5, wherein: The one-piece polymeric cover structure includes a forwardly opening pocket formed by pocket structure integrally formed with upper ends of the left and right outer structures; and includes: a padded headrest disposed adjacent the forwardly opening recess; and A support structure interconnects the headrest with the back portion of the frame.

7. A user support as claimed in claim 5 or claim 6, wherein: The left outer structure and the right outer structure extend upwardly from the base and inwardly toward each other.

8. A user support as claimed in any one of claims 5 to 7, wherein: The single-piece polymer cover structure includes an integral porous grid matrix extending across the gap between the elongated front and rear structures, wherein the integral porous grid matrix between the elongated front and rear structures has an exposed outer side that is visible.

9. A user support as claimed in any one of claims 5 to 8, wherein: The elongated front and rear structures include a porous grid matrix and an impermeable outer layer extending around and encapsulating the porous grid matrix.

10. A user support as claimed in any one of claims 1 to 9, wherein: The base of the one-piece polymer cover structure includes a porous grid matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous grid matrix, wherein the porous grid matrix of the base of the one-piece polymer cover structure extends horizontally across a lower portion of the base of the one-piece polymer cover structure.

11. A user support as claimed in any one of claims 1 to 10, comprising: A sound channel having a first end, the first end being configured to be operably coupled to a sound source whereby sound enters the first end of the sound channel, the sound channel having a second end, the second end having at least one opening formed in the one-piece polymer cover structure whereby sound entering the first end exits the at least one opening, and wherein at least a portion of the channel comprises a tube structure, the tube structure being integrally formed with the porous grid structure of the one-piece polymer cover structure.

12. A user support as claimed in any one of claims 1 to 11, wherein: The at least one cushion includes a plurality of cavities formed in the rear material layer; and The one-piece polymer cover structure includes a plurality of protrusions positioned within the cavity of the at least one cushion.

13. A method of manufacturing a user support for a vehicle, the method comprising: providing a frame having a lower portion and an upright back portion; forming a homogenous, one-piece polymer cover structure using an additive process, including forming an outer layer of polymer material extending around at least a portion of a porous grid substrate such that the outer layer of polymer material is integrally formed with the porous grid substrate; and A resilient pad is secured to the front side of the one-piece polymer cover structure.

14. The method of claim 13, comprising: The resilient cushions are formed using an additive process from a material having greater elasticity than the polymer material of the cover structure, the at least one cushion comprising a resilient porous grid matrix.

15. A method as claimed in claim 13 or claim 14, comprising: An additive process is used to form a sound tube extending upward through the porous grid matrix, wherein the sound tube is integrally formed with the porous grid matrix and forms an opening on the front side of the single-piece polymer cover structure.

Images