Vehicle user support including flexible lighting feature

Abstract

The present disclosure provides a vehicle user support including a flexible lighting feature. A user support for a motor vehicle includes a flexible cover having a flexible lamp including an electroluminescent material that emits light when power is supplied to the electroluminescent material. The user support may include an elastic porous mesh matrix formed by an additive process, and may include an electroluminescent material disposed on links of the mesh matrix.

Description

Technical Field

[0001] The present disclosure generally relates to a user support assembly for a vehicle, and more particularly to a user support assembly having lighting features that can be flexible. Background Art

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

[0003] One aspect of the present disclosure is a user support (seat) for a motor vehicle. The user support may include a lower portion having an upwardly facing cushioned user support surface and a back portion having a forwardly facing user support surface. A flexible cover extends over at least a portion of a selected one of the lower portion and the back portion. The user support further includes an electrical conductor disposed on an inner side of the flexible cover. The flexible cover includes a flexible light extending along a portion of the flexible cover. The flexible light includes a flexible electroluminescent material electrically connected to the electrical conductor, whereby when power is supplied to the flexible electroluminescent material through the electrical conductor, the flexible electroluminescent material emits light.

[0004] ● The flexible light may include a strip of flexible opaque material, wherein at least a portion of the strip of flexible opaque material is disposed on an inner side of the flexible electroluminescent material.

[0005] ● The strip of flexible opaque material may be wider than the electroluminescent material, and opposite edge portions of the strip of flexible opaque material may be wrapped around opposite edges of the flexible electroluminescent material, whereby the opposite edge portions of the strip of flexible opaque material are disposed on an outer side of the flexible electroluminescent material, and a central portion of the strip of flexible opaque material is disposed on an inner side of the flexible electroluminescent material.

[0006] ● The user support may include a suture passing through the opposite edge portions of the strip of flexible opaque material and through the flexible electroluminescent material, thereby interconnecting the flexible electroluminescent material with the opposite edge portions of the strip of flexible opaque material.

[0007] ● The flexible cover may include a flexible opaque material having an elongated opening therethrough, with spaced-apart edges extending along opposite sides of the elongated opening.

[0008] ● The flexible opaque material strip can be connected to the flexible opaque material of the flexible cover by a suture, the suture extending through the flexible opaque material strip and through the flexible opaque material of the flexible cover adjacent to the spaced-apart edges of the flexible opaque material of the flexible cover.

[0009] ● The electrical conductor disposed on the inner side of the flexible cover may include a metal printed on the inner side of the flexible cover.

[0010] ● The user support may include a pad, the pad including an elastic porous grid matrix formed by an additive process, wherein the elastic porous grid matrix has a plurality of links, the plurality of links interconnected to form a one-piece polymer structure.

[0011] ● At least one selected link of the links may include an electroluminescent material that emits light when power is supplied to the electroluminescent material.

[0012] ● At least one link of the elastic porous grid matrix may include an elongated polymer core coated with an electroluminescent material.

[0013] ● All of the links of the elastic porous grid matrix may optionally be coated with an electroluminescent material.

[0014] ● The user support may include at least one LED fixed to a link of the elastic porous grid matrix.

[0015] ● The pad may have: an elastic front surface configured to support a user; and a rear surface including a material layer integrally formed with the elastic porous grid matrix, wherein the material layer includes openings therethrough. The LED may be aligned with the openings such that light emitted by the LED passes through the openings and into the elastic porous grid matrix.

[0016] Another aspect of the present disclosure is a user support for a motor vehicle. The user support may include a frame and a pad, the pad including an elastic porous grid matrix formed by an additive process, wherein the elastic porous grid matrix has a plurality of links, the plurality of links interconnected to form a one-piece polymer structure. At least one selected link of the links may include an electroluminescent material that emits light when power is applied to the electroluminescent material.

[0017] ● At least one link of the elastic porous grid matrix may include an elongated polymer core coated with an electroluminescent material.

[0018] ● All of the links of the elastic porous grid matrix may be coated with an electroluminescent material.

[0019] ● At least one LED may be fixed to a link of the elastic porous grid matrix.

[0020] Another aspect of the present disclosure is a user support for a motor vehicle. The user support may include a frame and a padding, the padding including an elastic porous grid matrix formed by an additive process, wherein the elastic porous grid matrix has a plurality of links that are interconnected to form a one-piece polymer structure. The user support includes at least one LED fixed to a link of the elastic porous grid matrix.

[0021] ● The user support includes a plurality of LEDs fixed to the links of the elastic porous grid matrix.

[0022] ● At least one selected link of the links may include an electroluminescent material that emits light when power is supplied to the electroluminescent material.

[0023] Those skilled in the art will further understand and appreciate these and other features, advantages, and objectives of the present disclosure by referring to the following specification, claims, and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In the drawings:

[0025] Figure 1 is a perspective view of a user support according to one aspect of the present disclosure;

[0026] Figure 2 is Figure 1 a perspective view of the user support;

[0027] Figure 3 is a perspective view of a user support according to another aspect of the present disclosure;

[0028] Figure 4 is Figure 3 an isometric view of the user support;

[0029] Figure 5 is a schematic partial side elevation view of the user support;

[0030] Figure 6 is Figure 1 a schematic cross-sectional view taken along line VI-VI of the user support;

[0031] Figure 7 is Figure 6 an enlarged cross-sectional view of a portion of the user support;

[0032] Figure 8 is a partial cross-sectional view of a lamp according to one aspect of the present disclosure;

[0033] Figure 9 is a partial cross-sectional view of a lamp according to another aspect of the present disclosure;

[0034] Figure 10 is a partial perspective view showing the assembly of a lamp according to one aspect of the present disclosure;

[0035] Figure 11 is a partial perspective view showing the assembly of a lamp according to one aspect of the present disclosure;

[0036] Figure 12 is a partial perspective view showing the assembly of a lamp according to one aspect of the present disclosure;

[0037] Figure 13 is a partial perspective view showing the assembly of a lamp according to one aspect of the present disclosure;

[0038] Figure 14 is a partial exploded perspective view of a user support during assembly;

[0039] Figure 15 is Figure 14 an enlarged view of a part of the user support;

[0040] Figure 16 is Figure 14 an enlarged view of a part of the user support;

[0041] Figure 17 is a partial schematic view of a lamp arrangement according to another aspect of the present disclosure;

[0042] Figure 18 is Figure 3 a cross-section of the user support taken along line XVII-XVII;

[0043] Figure 19 is a perspective view of a single grid element;

[0044] Figure 20 is a perspective view of the first step of an array setup;

[0045] Figure 21 is a perspective view of the second step of an array setup;

[0046] Figure 22 is a perspective view of the third step of an array setup;

[0047] Figure 23 is a perspective view showing the conformal setup of an array;

[0048] Figure 24is a perspective view showing a cross-hatched porous housing;

[0049] Figure 25A is a perspective view showing a single grid element of a base layer or structure;

[0050] Figure 25B is a perspective view of the grid element of FIG. 25 after forming the second layer;

[0051] Figure 25C is a perspective view of the grid element of FIG. 25 after forming the third layer;

[0052] Figure 25D is a perspective view of the grid element of FIG. 25 after forming the second layer;

[0053] Figure 26 is Figure 25D a cross-sectional view of the grid element taken along line XXVI-XXVI;

[0054] Figure 27 is Figure 26 an enlarged view of the grid element;

[0055] Figure 28 is a partially schematic perspective view showing a single grid element with an LED attached thereto; and

[0056] Figure 29 is Figure 29 a partial schematic view of the grid element having an LED attached to the grid element. DETAILED DESCRIPTION

[0057] This application is related to U.S. Patent Application No. 18 / 541,404, titled "VEHICLE USER SUPPORT INCLUDING UPPER HOOD MODULE" (Attorney Docket No. 84805763), filed on the same day as this application, and U.S. Patent Application No. 18 / 541,739, titled "USER SUPPORT ASSEMBLY FOR VEHICLES" (Attorney Docket No. 84805943), filed on the same day as this application, the entire contents of each of which are incorporated herein by reference.

[0058] 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.

[0059] As needed, the present disclosure discloses detailed embodiments of the present disclosure; however, it should be understood that the disclosed embodiments are merely examples of the present disclosure, which may be implemented in various alternative forms. The accompanying drawings are not necessarily detailed designs; some schematic diagrams may be enlarged or minimized to show a functional overview. Therefore, the specific structural details and functional details disclosed herein should not be construed as restrictive, but merely as a representative basis for teaching those skilled in the art to adopt the present disclosure in different ways.

[0060] The illustrated embodiments mainly exist in the combination of method steps and device components related to user supports. Therefore, the device components and method steps have been represented by conventional symbols in the drawings where appropriate, showing only those specific details relevant to understanding the embodiments of the present disclosure, so as not to obscure the present disclosure with details that are readily apparent to those of ordinary skill in the art who benefit from the description herein. In addition, the same reference numerals in the specification and drawings denote the same elements.

[0061] 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 employed alone, or any combination of two or more of the listed items can be employed. 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.

[0062] 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 existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0063] 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 to reflect tolerances, conversion factors, rounding, measurement errors, and other factors known to those of skill 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 the present specification recite "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 the endpoints of each of the ranges are significant both in relation to and independent of the other endpoint.

[0064] 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 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.

[0065] 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.

[0066] For purposes of description herein, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", and derivatives thereof shall refer to the concepts of orientation as Figure 1 oriented in. However, it should be understood that unless explicitly specified to the contrary, the concepts may assume various alternative orientations. It should also be understood that the specific devices and processes shown in the figures 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.

[0067] User support 1( Figure 1 and Figure 2 ) and user support 1A( Figure 3 and Figure 4)is generally configured to support a user in a motor vehicle 2 or the like. The user supports 1 and 1A include a lower portion 4 and a back portion 6. The lower portion 4 has an upwardly facing cushioned user support surface 5, and the back portion 6 has a forwardly facing user support surface 7. The user supports 1, 1A may be configured to be fixed to the floor 3 of the vehicle 2( Figure 5 ). A flexible cover 10 (e.g., covers 10A, 10B) extends over at least a portion of a selected one of the lower portion 4 and the back portion 6. In the illustrated example, separate covers 10A and 10B are used on the lower portion 4 and the back portion 6. However, it should be understood that a single cover may extend over the lower portion 4 and the back portion 6, or the user supports 1, 1A may utilize a cover 10A or 10B on only one of the lower portion 4 and the back portion 6. The covers 10A and 10B may include leather, vinyl, fabric, or other suitable materials.

[0068] The user support 1( Figure 1 and Figure 2 ) may include an upper support 12 connected to the back portion 6. The user support 1A( Figure 3 and Figure 4 ) may include an upper module 14, which includes an upper support 12A. The user support 1A may include upper cushions 90A and 90B. The cushions 90A and 90B may be mirror images of each other. It should be understood that Figures 1 to 5 the user supports 1 and 1A are merely examples of user supports, and the present disclosure is not limited to Figures 1 to 5 the specific configurations.

[0069] The flexible cover 10 (e.g., covers 10A, 10B) may include a light 20 extending along a portion of the flexible covers 10A, 10B (see also Figure 5 ). The light 20 includes a flexible electroluminescent material, such as a light strip 22 (see also Figure 8 and Figure 9 ). Although the material 22 is referred to herein as a "light strip", it should be understood that the material 22 may actually have any size and shape required for a particular application, and the present disclosure is not limited to strips or other particular configurations. The light strip 22 may include a phosphor layer combined with one or more other material layers. The electroluminescent material may include commercially available materials having several "coating" layers applied in a known sequence / process. As discussed in more detail below, when power is supplied to the light strip 22, the electroluminescent material of the light strip 22 emits light. The light strip 22 is electrically connected to an electrical conductor 18 (see also Figure 6 and Figure 7), whereby when power from power supply 24 is supplied to light strip 22 through electrical conductor 18, the electroluminescent material of light strip 22 emits light. Power supply 24( Figure 5 and Figure 6 ) may include a battery or electrical line operably connected to main vehicle power supply 26 in vehicle control system 28. Generally, vehicle control system 28 may include numerous sensors, modules, and networks. Vehicle control system 28 may include one or more user inputs 30. User inputs may include, for example, switches, touchscreens located on the vehicle, or other input features that allow a user to control when power is supplied to light strip 22. Vehicle control system 28 may be configured to provide illumination of light strip 22 when, for example, vehicle interior lights and / or exterior lights are illuminated, a vehicle door is opened, a low level of light inside or outside the vehicle is detected by sensors in control system 28, etc.

[0070] Referring again to Figure 6 and Figure 7 , conductor 18 may include a conductive material deposited (e.g., printed) on inner surface 32 of material layer 34 of cover 10A or 10B. Layer 34 may include a fabric, vinyl, leather, or a combination of layers of such materials. Conductor material 18 deposited on layer 32 may include Liquid Printed Metals of Pennsylvania conductive metal. A portion 19 of conductor 18 may optionally include a wire that electrically interconnects light strip 22 to power supply 24.

[0071] Support structures 1, 1A( Figure 6 ) may include a frame 15 having a lower portion 16 and an upper portion 17. The user support may also include resilient supports 50A and 50B, which respectively include resilient porous grid matrix structures 48A and 48B. Porous grid matrix structures 48A and 48B may include polymer structures formed using an additive process (e.g., 3D printing), as more particularly described in co-pending applications titled "VEHICLE USER SUPPORT INCLUDING UPPER HOOD MODULE" (Attorney Docket No. 84805763) and "USER SUPPORT ASSEMBLY FOR VEHICLES" (Attorney Docket No. 84805943), which are incorporated herein by reference above. User support 1 may optionally include foams 49A and 49B. Moreover, covers 10A and 10B may optionally not extend respectively above front surfaces 52A and 52B of grid structures 48A, 48B such that front surfaces 52A, 52B may be at least partially exposed. As described below in connection with Figures 19 to 27As discussed, one or both of the grid structures 48A, 48B can include one or more LED light sources 126( Figure 5 , Figure 28 , Figure 29 ) and / or an electroluminescent material 118( Figure 27 ) that emits light. The light emitted from the LED 126 and / or the electroluminescent material can be emitted from one or both surfaces 52A, 52B of the grid structures 48A, 48B, respectively.

[0072] The lamp 20 can have various configurations, such as Figure 8 the lamp 20A or Figure 9 the lamp 20B. The lamp 20A( Figure 8 ) includes a thermoplastic polyolefin (TPO) layer 36 adhered to a lamp strip 22. The material of the lamp strip 22 can be sprayed onto the surface 38 of the TPO 36. Alternatively, the lamp strip 22 can be prefabricated and adhered to the surface 38 of the TPO 36 using an adhesive, heat pressing, or other suitable process. The lamp strip 22 includes elongated electrical conductors, such as electrical buses 40A and 40B, that extend along the lamp strip 22 adjacent its opposite side edges 42A and 42B, respectively. The buses 40A and 40B of the lamp strip 22 can be electrically coupled to a first electrical wire 18A and a second electrical wire 18B disposed on the layer 34 of the coverings 10A, 10B. The conductors 18A and 18B can include positive and negative alternating current (“AC”) inputs to the lamp strip 22. In Figure 8 , the buses 40A and 40B are shown protruding from the surface 23 of the lamp strip 22. However, it should be understood that the buses 40A and 40B can be flush with the surface 23, as shown by the dashed line 41.

[0073] Further referring to Figure 9 , the lamp 20A includes a lamp strip 22 that is operatively connected to the conductors 18A and 18B in substantially the same manner as described above in Figure 8 . The lamp 20B also includes a TPO layer 36. The lamp 20B also includes a fabric layer 44 disposed on the surface 45 of the TPO layer 36. The fabric 44 can be adhered, heat-sealed, or otherwise fixed to the surface 45 of the TPO layer 36. Preferably, the lamp strip 22 includes a multi-layer structure sprayed onto the surface 38 of the layer 36. For example, the lamp strip 22 can be formed using coatings applied sequentially according to known processes.

[0074] Figure 8 The TPO layer 36 of the lamp 20A of Figure 9The TPO layer 36 of the lamp 20B has a thickness "T2". Generally, the thickness T1 can (optionally) be greater than the thickness T2. For example, the thickness T1 can be from about 0.020 inches to 0.060 inches, while the thickness T2 can be, for example, from 0.010 inches to 0.030 inches. It should be understood that these ranges are merely examples, and the actual thicknesses T1 and T2 can vary depending on the composition of the TPO layer 36, the profile of the cover, and / or other factors. For example, the fabric layer 44 can reduce the flexibility of the lamp 20D, such that a slightly thinner TPO layer 36 can be utilized to provide sufficient flexibility to allow the lamp 20D to conform to various curves of the cover 10A or 10B. Moreover, it should be understood that the layer 36 can include other suitable materials, and the present disclosure is not limited to TPO or any other specific material.

[0075] Referring again to Figure 9 , the layer 45 can optionally include a plurality of perforations 54 that allow the light "L" emitted by the light strip 22 to pass through the perforations 54 of the layer 44. For example, if the layer 44 includes leather, vinyl, or other opaque materials, the perforations 54 can be utilized to allow light to pass through the layer 44.

[0076] The lamp 20 can be fixed to the flexible cover 10A or 10B, as Figures 10 to 13 shown. As Figure 10 shown, an opening in the form of an elongated gap or slot 56 can be formed between the edges 58A and 58B of the covers 10A, 10B. Generally, the gap or slot 56 can be formed by cutting the material to form the edges 58A and 58B. Alternatively, or in addition, the covers 10A, 10B can include two separate pieces of material that are adjacent to each other to form the gap or slot 56. The gap 56 can have almost any shape and size as needed, and the present disclosure is not limited to an elongated slot.

[0077] The material 60 is positioned above the slot 56 and is fixed to the cover 10A by sutures 62, leaving flaps 64A and 64B. The sutures 62 can include thread or other suitable material 60, which can include vinyl, fabric, leather, or other suitable materials, and the material 60 can include a material similar to that of the cover 10A, or the material 60 can include a significantly different (e.g., different color, different texture, etc.) material. In the example shown, the material 60 is in the form of an elongated strip. However, the material 60 can actually have any size and shape.

[0078] Referring further to Figure 11 , the lamp 20 can be positioned above the central portion 66 of the material 60, where the opposite edges 68A and 68B of the lamp 20 are positioned adjacent to the sutures 62. The lamp 20 can include the lamp 20A ( Figure 8) or lamp 20B( Figure 9 ), and may include conductive electrical buses 40A and 40B that can be positioned against the upper surface 67 of the material 60.

[0079] Further reference Figure 12 and Figure 13 , the flaps 64A and 64B can be wrapped around the edges 68A and 68B of the lamp 20 respectively, and the suture 70 can be stitched in place to hold the flaps 64A and 64B in Figure 13 the final position. Generally, the suture 70 can extend through the flaps 64A, 64B, through the lamp 20, and through the outer portions 72A and 72B of the material 60. As Figure 13 shown, the central portion 74 of the lamp 20 is not covered by the material 60, such that the light emitted by the lamp 20 is readily visible from the outside of the cover 10A or 10B. Portions 76A and 76B of the conductive buses 40A and 40B can optionally project outwardly and / or downwardly beyond the ends 78 of the lamp 20 to provide an electrical connection to the electrical conductor 18.

[0080] Further reference Figures 14 to 15 , two lamps 20 can be positioned on the cover 10 (e.g., cover 10A or 10B) of the back portion 6 of the user support 1, 1A, where the ends 78 of adjacent lamps 20 are positioned directly adjacent to each other at the seam 80. The buses 40A, 40B of the lamp 20 can be electrically connected to the electrical conductor 18 (e.g., portions 76A, 76B, Figure 13 ) using solder, an electrical crimp connector, or other suitable arrangement. The conductor 18 can include a first conductor and a second conductor having opposite polarities, and each conductor 18 can be connected to the buses 40A, 40B of the lamp 20. Alternatively, four conductors 18 can be utilized, whereby two conductors 18 are operably connected to the first lamp 20, and a second pair of conductors 18 is attached to the other lamp 20.

[0081] Further reference Figure 16 , a flexible material sheet 82 can be positioned above the seam 80 and secured to the cover 10B using stitching, an adhesive, or other suitable arrangement. For example, the material sheet 82 can include flexible leather, vinyl, fabric, or other suitable material, and a design such as letters 84 can be sewn onto the material sheet 82 to provide a decorative appearance. It should be understood that the lamp 20 can have almost any size or shape and can be located at any suitable position on the user support.

[0082] Further reference Figure 17, according to another aspect of the present disclosure, the lamp assembly 85 includes a lamp 20 located on the inner sides of the covers 10A, 10B, whereby light L emitted by the lamp 20 passes through the perforations 54 in the material of the covers 10A, 10B. The lamp 20 may include an electroluminescent material 22 and a layer 36. The layer 36 may include TPO or other suitable materials as discussed in more detail above. The lamp 20 may be fixed to the inner surface of the cover 10 (e.g., covers 10A, 10B) by an adhesive, heat sealing, or other suitable process. An optional cover 86 may extend above the rear side of the lamp 20. The edge portion 87 of the cover 86 may be fixed to the inner surface 32 of the cover 10 by heat sealing, an adhesive, or stitching. The lamp 20 may optionally be fixed to the covers 10A, 10B using stitching threads 88.

[0083] The lamp 20 of the lamp assembly 85 ( Figure 17 ) is positioned adjacent to (behind) an opening or perforation 54 through the material of the covers 10A, 10B, whereby light L generated by the lamp 20 passes through the opening 54, such that the lamp 20 of the lamp assembly 85 can be positioned at substantially any location on the covers 10A, 10B of the user support.

[0084] Further referring Figure 18 , the cushions 90A, 90B of the user support 64 ( Figure 3 ) may include an elastic porous grid 92 formed using an additive process (3D printing), and may respectively include an integrally formed front layer 93 and a rear layer 94. The grid 92 and the layers 93 and 94 may include a polymer or other suitable materials, and the front layer 32 may be elastic to provide a desired degree of cushioning. The rear layer 94 may include an opening 98 in a recess 96. The LED light source 97 may be positioned in the recess 96 to project light "L" through the matrix 92 and through an optional perforation 54 in the front layer 93. The LED light source 97 may be aligned with the opening 98 in the rear layer 94 to allow light to pass through the rear layer 94. The front layer 93 may include perforations 54 to allow light to pass through the layer 93. Alternatively, the cushions 90A, 90B may be formed without the front layer 93, such that the front surface 99 of the porous grid is exposed, whereby light L escapes through the front surface 99 of the porous grid 92. The LED 97 may be operably connected to a power source via a conductor 18.

[0085] Figures 19 to 24 Illustrated is the formation of the upper cushions 90A, 90B using a 3D additive process. Initially, a single structural unit or element 100 ( Figure 19 ) may be formed, then an array 102 of interconnected elements ( Figure 20 ) may be formed, and subsequently a two-dimensional array or layer 104 ( Figure 21 ) may be formed. Additional layers of the element 100 may be added to form an array 106 ( Figure 22)。Then a conformal setting can be utilized to form a three-dimensional porous grid matrix, such as array 108( Figure 23 )。Then a cross-hatched outer shell 110 can be formed( Figure 24 )。The outer shell 110 is preferably porous and extends around the pads 90A and 90B (see also Figure 3 、 Figure 4 and Figure 18 ). It should be understood that pads of various shapes and sizes can be formed using the processes described herein, and the present disclosure is not limited to the specific pads 90A and 90B. The array 108 can include a one-piece homogeneous polymer structure.

[0086] Further reference is made to Figures 25A to 25D , one or more of the grid elements can include an outer layer of an electroluminescent material, whereby when power is supplied to an individual grid element, the individual grid element emits light. Referring to Figure 25A , the base layer or structure 112 of the porous grid matrix (e.g., array 108) can be formed from a suitable polymer material (such as TPU) using an additive process. Then the backing layer 114( Figure 25B ) is applied over the TPU base structure 112. Then the dielectric layer 116( Figure 25C ) is applied over the backing layer 114, and then the electroluminescent layer 118( Figure 25D ) is applied to form a layer or structure 120 that emits light when power is supplied to the structure 120. The layers 114, 116, and 118 can include commercially available materials applied using a spraying process, an impregnation process, or a 3D additive (printing) process.

[0087] Further reference is made to Figure 26 and Figure 27 , the cross-section 122 of the structure 120 includes the base TPU structure 112, the backing layer 114, the dielectric layer 116, and the electroluminescent outer layer 118. One or more conductive elements 124 can be operably interconnected to one or more of the layers 114, 116, 118 to supply power, whereby the electroluminescent outer layer 118 emits light.

[0088] Generally, one or more individual grid elements of the pads 90A, 90B can include grid elements 120 that emit light when power is supplied to them. It should be understood that selected grid elements among the individual grid elements can be electrically connected to a power source in such a way that only the selected grid elements among the grid elements are allowed to light up, whereby a lit pattern can be formed. Moreover, the grids of the pads 90A, 90B can only include some portions having electroluminescent materials, whereby only some portions of the porous grid 92 can be lit.

[0089] Further reference is made to Figure 20 andFigure 29 , one or more LEDs 126 may be adhered or otherwise attached to one or more grid elements 128. The LED 126 includes a conductor 130 that may be operably connected to a power source such that the LED 126 emits light. In addition to or instead of the LED 97, the LED 126 may be positioned in the porous grid 92 of the pads 90A and 90B ( Figure 18 ) to provide light. The grid element 128 may optionally include a lighted layer or structure 120 ( Figure 26 and Figure 27 ), or the grid element 128 may include a polymeric material that does not include an external electroluminescent material 118.

[0090] It should be understood that the foregoing structures may be changed and modified without departing from the concepts 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 state otherwise expressly by their language.

[0091] According to the present invention, there is provided a user support for a motor vehicle, the user support having: a lower portion having an upwardly facing cushioned user support surface; a back portion having a forwardly facing user support surface; a flexible cover extending over at least a portion of a selected one of the lower portion and the back portion; an electrical conductor disposed on an inner side of the flexible cover; the flexible cover including a flexible light extending along a portion of the flexible cover; the light including a flexible electroluminescent material electrically connected to the electrical conductor, whereby the electroluminescent material emits light when power is supplied to the electroluminescent material through the electrical conductor.

[0092] According to an embodiment, the flexible light includes a layer of flexible opaque material, wherein at least a portion of the layer of flexible opaque material is disposed on an inner side of the flexible electroluminescent material.

[0093] According to an embodiment, the flexible opaque material layer and the flexible electroluminescent material include elongated flexible strips, wherein the elongated flexible strip of the opaque material is wider than the elongated flexible strip of the electroluminescent material; opposite edge portions of the elongated flexible strip of the opaque material extend around opposite edges of the elongated flexible strip of the electroluminescent material, whereby the opposite edge portions of the elongated flexible strip of the opaque material are disposed on an outer side of the elongated flexible strip of the electroluminescent material, and a central portion of the elongated flexible strip of the opaque material is disposed on an inner side of the elongated flexible strip of the electroluminescent material.

[0094] According to an embodiment, the invention is further characterized in that: a suture, the suture extending through the opposite edge portions of the elongated flexible strip of the opaque material and through the elongated flexible strip of the electroluminescent material, thereby interconnecting the elongated flexible strip of the electroluminescent material with the opposite edge portions of the flexible strip of the opaque material.

[0095] According to an embodiment, the flexible cover includes a flexible opaque material having an elongated opening therethrough, with spaced-apart edges extending along opposite sides of the elongated opening.

[0096] According to an embodiment, the elongated flexible strip of the opaque material is connected to the elongated flexible strip of the opaque material of the flexible cover of the flexible cover by a suture that extends through the elongated flexible strip of the opaque material and through the spaced-apart edges of the flexible opaque material adjacent to the flexible cover.

[0097] According to an embodiment, the electrical conductor includes metal printed on the inner side of the flexible cover.

[0098] According to an embodiment, the invention is further characterized in that: a porous grid matrix formed by an additive process, the porous grid matrix having a plurality of links, the plurality of links interconnected to form a one-piece polymer structure.

[0099] According to an embodiment, at least one selected link of the links includes an electroluminescent material that emits light when power is supplied to the electroluminescent material.

[0100] According to an embodiment, at least one link of the porous grid matrix includes an elongated polymer core coated with an electroluminescent material.

[0101] According to an embodiment, the links of the elastic porous grid matrix are coated with an electroluminescent material.

[0102] According to an embodiment, the invention is further characterized in that at least one LED, the at least one LED being fixed to a link of the porous grid matrix.

[0103] According to an embodiment, the porous grid matrix has an elastic front surface configured to support a user and a rear surface including a material layer integrally formed with the porous grid matrix, wherein the material layer includes an opening therethrough; and the user support includes: an LED, the LED being aligned with the opening, whereby light emitted by the LED passes through the opening and into the porous grid matrix.

[0104] According to the present invention, there is provided a user support for a motor vehicle, the user support having: a frame; a porous grid matrix formed by an additive process, the porous grid matrix having a plurality of links, the plurality of links being interconnected to form a one-piece polymer structure; and wherein: at least one selected link of the links includes an electroluminescent material that emits light when power is supplied to the electroluminescent material.

[0105] According to an embodiment, at least one link of the porous grid matrix includes an elongated polymer core coated with an electroluminescent material.

[0106] According to an embodiment, the links of the porous grid matrix are coated with an electroluminescent material.

[0107] According to an embodiment, at least one LED is fixed to a link of the porous grid matrix.

[0108] According to the present invention, there is provided a user support for a motor vehicle, the user support having: a frame; a porous grid matrix formed by an additive process, the porous grid matrix having a plurality of links, the plurality of links being interconnected to form a one-piece polymer structure; and at least one LED, the at least one LED being fixed to a link of the porous grid matrix.

[0109] According to an embodiment, the present invention is further characterized by a plurality of LEDs fixed to the porous grid matrix.

[0110] According to an embodiment, at least one selected link of the links includes an electroluminescent material that emits light when power is supplied to the electroluminescent material.

Claims

1. A user support for a motor vehicle, the user support comprising: a lower portion having an upwardly facing cushioned user support surface; a back portion having a forward facing user support surface; a flexible cover extending over at least a portion of a selected one of the lower portion and the back portion; an electrical conductor disposed on an inner side of the flexible cover; The flexible cover includes a flexible light extending along a portion of the flexible cover; The lamp comprises a flexible electroluminescent material electrically connected to the electrical conductor, whereby the electroluminescent material emits light when electrical power is supplied to the electroluminescent material through the electrical conductor.

2. A user support according to claim 1, wherein: The flexible lamp includes a layer of flexible opaque material, wherein at least a portion of the layer of flexible opaque material is disposed on an inner side of the flexible electroluminescent material.

3. A user support according to claim 2, wherein: said layer of flexible opaque material and said flexible electroluminescent material comprising elongated flexible strips, wherein said elongated flexible strips of opaque material are wider than said elongated flexible strips of electroluminescent material; Relative edge portions of the elongated flexible strip of opaque material extend around relative edges of the elongated flexible strip of electroluminescent material, whereby the relative edge portions of the elongated flexible strip of opaque material are disposed on the outside of the elongated flexible strip of electroluminescent material and the center portion of the elongated flexible strip of opaque material is disposed on the inside of the elongated flexible strip of electroluminescent material.

4. A user support according to claim 3, comprising: A stitch extends through the opposing edge portions of the elongated flexible strip of opaque material and through the elongated flexible strip of electroluminescent material to interconnect the elongated flexible strip of electroluminescent material with the opposing edge portions of the flexible strip of opaque material.

5. A user support according to claim 4, wherein: The flexible cover includes a flexible opaque material having an elongated opening therethrough with spaced-apart edges extending along opposite sides of the elongated opening.

6. A user support according to any one of claims 3 to 5, wherein: The elongated flexible strip of opaque material is connected to the elongated flexible strip of opaque material of the flexible cover by stitching extending through the elongated flexible strip of opaque material and through the elongated flexible opaque material of the flexible cover adjacent the spaced-apart edges of the flexible opaque material of the flexible cover.

7. A user support according to any one of claims 1 to 6, wherein: The electrical conductor comprises metal printed on the inner side of the flexible cover.

8. A user support according to any one of claims 1 to 7, comprising: A porous mesh matrix formed by an additive process, the porous mesh matrix having a plurality of links interconnected to form a one-piece polymer structure.

9. A user support according to claim 8, wherein: At least one selected one of the links includes an electroluminescent material that emits light when power is supplied to the electroluminescent material.

10. A user support according to claim 8 or claim 9, wherein: At least one link of the porous grid matrix includes an elongated polymer core coated with an electroluminescent material.

11. A user support according to claim 10, wherein: The links of the elastic porous mesh matrix are coated with an electroluminescent material.

12. A user support according to any one of claims 8 to 11, comprising: At least one LED is secured to a link of the porous grid matrix.

13. A user support according to any one of claims 8 to 12, wherein: The porous mesh matrix has a resilient front surface configured to support a user and a rear surface comprising a layer of material integrally formed with the porous mesh matrix, wherein the layer of material includes openings therethrough; and the user support comprises: An LED is aligned with the opening such that light emitted by the LED passes through the opening and enters the porous mesh matrix.

14. A user support for a motor vehicle, the user support comprising: frame; A porous mesh matrix formed by an additive process, the porous mesh matrix having a plurality of links interconnected to form a one-piece polymer structure; and wherein: At least one selected one of the links includes an electroluminescent material that emits light when power is supplied to the electroluminescent material.

15. A user support for a motor vehicle, the user support comprising: frame; a porous mesh matrix formed by an additive process, the porous mesh matrix having a plurality of links interconnected to form a one-piece polymer structure; as well as At least one LED is secured to a link of the porous grid matrix.

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