ADAPTABLE AND RECONFIGURATED OCCUPANT SUPPORT STRUCTURE

Abstract

Occupant support structure (300), comprising: a base (334); a reconfigurable cushion (336) supported by the base (334) and adapted to support a body part of an occupant (340), wherein the reconfigurable cushion (336) includes an occupant support surface (346) and a bladder (310) with an outer wall (312) defining an inner cavity (314) beneath the occupant support surface (346) and two or more overlapping material layers (316) arranged in the cavity (314), and one or more prestressing elements (338) arranged between the base (334) and the reconfigurable cushion (336), wherein the one or more prestressing elements (338) are configured to prestress the cushion (336) away from the base and to resist movement of the cushion (336) towards the base in response to an external load applied by an occupant (340) to the occupant support surface (346) of the cushion (336), wherein the overlapping material layers (316) are designed to selectively transition from a compliant state to a rigid state and vice versa by selectively controlling a pressure state across the outer wall (312) of the bladder (310) or to adapt the occupant support surface (346) of the cushion (336) to a contour of a body part of an occupant (340) that is supported by the cushion (336), wherein, when atmospheric pressure is created across the outer wall (312) of the bladder (310), the overlapping material layers (316) are adapted to exhibit a compliant state and to deform in response to an external load exerted by an occupant (340) on the occupant support surface (346) of the cushion (336), and wherein, when a negative pressure condition is created across the outer wall (312) of the bladder (310), the overlapping material layers (316) are adapted to exhibit the rigid state and to prevent deformation of the occupant support surface (346) in response to the application or removal of an external load to the occupant support surface (346) of the cushion (336).

Description

TECHNICAL AREA

[0001] The present disclosure relates generally to occupant support structures and to methods for adapting occupant support structures. INTRODUCTION

[0002] A vehicle occupant support structure can be designed to allow the occupant to reposition it, optimizing comfort and vehicle usability. For example, vehicle seats may be designed to allow horizontal, vertical, and / or tilt adjustments to accommodate occupants of varying sizes, such as different body heights. In addition to adjusting the position of an occupant support structure, it may be desirable to enable the occupant to better adapt the structure's physical contours to their own, further optimizing comfort, functionality, and safety.To accommodate multiple different occupants of a vehicle, it may be desirable to give each occupant the ability to reconfigure the physical contours of the support structure to better conform to their individual physical shape.

[0003] A method and a device for joining layers are known from US patent 2015 / 0107233 A1. A multi-layered seat is described in German patent DE 102016104908 A1. A deformable device with fibrous material is described in US patent 2017 / 0341334 A1. A seat cushion device is described in US patent 2014 / 0333107 A1.

[0004] The purpose of the present disclosure is to provide an improved occupant support structure and an improved method for adapting such an occupant support structure. SUMMARY

[0005] This problem is solved by an occupant support structure according to independent claim 1 and by a method for adapting an occupant support structure according to independent claim 9. Advantageous further developments are specified in the dependent claims.

[0006] An occupant support structure comprises a base and a reconfigurable cushion supported by the base. The reconfigurable cushion is adapted to support a part of an occupant's body and includes an occupant support surface and a bladder. The bladder includes an outer wall defining an inner cavity beneath the occupant support surface and two or more overlapping layers of material arranged within the cavity. The overlapping layers of material are adapted to selectively transition from a compliant to a rigid state, and vice versa, by selectively controlling a pressure state across the outer wall of the bladder. When atmospheric pressure is established across the outer wall of the bladder, the overlapping layers of material are adapted to exhibit a compliant state and deform in response to an external load applied by an occupant to the occupant support surface of the cushion.When a negative pressure condition is created across the outer wall of the bladder, the overlapping material layers are designed to exhibit a rigid state and prevent deformation of the occupant support surface in response to the application or removal of an external load. Selective transition of the overlapping material layers from a compliant to a rigid state allows the occupant support surface of the pad to be reconfigured or adapted to the contour of an occupant's body part being supported by the pad.

[0007] According to the invention, the occupant support structure includes one or more pretensioning elements arranged between the base and the reconfigurable cushion. The one or more pretensioning elements are designed to pretension the cushion away from the base and to resist movement of the cushion towards the base in response to an external load exerted by an occupant on the occupant support surface of the cushion.

[0008] The overlapping material layers can be positioned within the cavity so that opposing surfaces of adjacent material layers are in direct contact with each other. The overlapping material layers can also be designed such that when a vacuum is created across the outer wall of the bubble, friction is generated between the opposing surfaces of the layers, thus preventing shearing.

[0009] At least one of the overlapping material layers may include a composite material comprising a network of rigid regions connected by one or more more compliant regions. The compliant regions may be designed to prestress the rigid regions against each other and resist relative movement of the rigid regions in response to an applied external load. In one mold, the rigid regions may be physically separated from each other by voids. In another mold, at least one of the overlapping material layers may also comprise a continuous layer of a physically and chemically homogeneous material.

[0010] The overlapping material layers can comprise alternating first and second layers. In one form, the first layers can have a different material composition or configuration than the second layers. For example, the first layers can comprise a rigid material and the second layers can comprise a flexible material.

[0011] The bladder may have an opening through which fluid can be drained from or introduced into the cavity to create a desired pressure condition within the cavity.

[0012] The occupant support structure may include a vacuum pump and a draining system for selectively creating a negative pressure condition within the cavity.

[0013] The reconfigurable cushion can include an elastomeric pad that lies over the bladder and a cover that lies over the elastomeric pad, and the occupant support area can be defined by the cover.

[0014] The reconfigurable cushion can include a first bladder and a second bladder. Each of the first and second bladders can include an outer wall defining an inner cavity beneath the occupant support surface and two or more overlapping layers of material arranged within their respective cavities. The first and second bladders can transition individually or together from a yielding state to a rigid state and vice versa by selectively controlling a pressure state across the outer walls of the first and second bladders. Selectively transitioning the first and second bladders from a yielding to a rigid state allows the first and second zones of the cushion's occupant support surface to be reconfigured or adapted to the contour of an occupant's body part supported by the cushion.

[0015] The reconfigurable cushion can include a seat back, a seat surface, an armrest, a footrest, or a headrest for a vehicle occupant.

[0016] A seat for a vehicle occupant can include the aforementioned occupant support structure. In this case, the seat can be a driver's seat, a front passenger seat, a child seat, or a booster seat.

[0017] A method for adapting a previously described occupant support structure includes providing a previously described occupant support structure. The method further includes establishing an initial pressure state across the outer wall of the bladder such that the cushion has an initial configuration. A first occupant can be positioned in contact with the occupant support surface of the cushion such that a body part of the first occupant presses against the occupant support surface, conforming the occupant support surface to a contour of the first occupant's body part. A second pressure state can be established across the outer wall of the bladder while the first occupant is in contact with the occupant support surface to frictionally engage the overlapping material layers and impart a predetermined stiffness to the cushion.The second pressure state can be maintained via the outer wall of the bladder, so that the occupant support surface retains the contour of the first occupant's body part.

[0018] The first pressure state can be established via the outer wall of the bladder by equalizing the pressure across the outer wall of the bladder.

[0019] The second pressure state can be created via the outer wall of the bladder by establishing a negative pressure state within the cavity.

[0020] The body part of the occupant can include the occupant's head, back, shoulder, lumbar region, buttocks, leg, arm, or foot.

[0021] The bladder can be returned to its initial pressure state to restore the cushion to its original configuration. A second occupant can then be positioned in contact with the cushion's occupant support surface, causing a body part of the second occupant to press against the support surface and conform to the contour of that body part. A second pressure state can be established across the outer wall of the bladder while the second occupant remains in contact with the support surface, creating frictional engagement with the overlapping material layers and imparting a predetermined stiffness to the cushion. This second pressure state can be maintained across the outer wall of the bladder, ensuring the support surface retains the contour of the second occupant's body part. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic cross-sectional view of a bubble in a compliant state, wherein the bubble includes an outer wall defining a cavity in which several thin overlapping layers of material are enclosed, according to one aspect of the present disclosure; Fig. Figure 2 is a schematic cross-sectional view of the bubble of Fig. 1 in a rigid state; Fig. Figure 3 is a top view of a thin layer of material comprising a network of rigid regions connected by compliant regions, according to one aspect of the present disclosure; Fig. Figure 4 is a top view of another thin layer of material comprising a network of rigid regions connected by compliant regions, according to another aspect of the present disclosure; Fig. Figure 5 is a schematic cross-sectional view of an occupant support structure with a base and a reconfigurable cushion, wherein body parts of an occupant are supported on an occupant support surface of the cushion; and Fig. Figure 6 is a perspective view of a vehicle seat comprising a seat surface, a seat back and a headrest, wherein the seat surface, the seat back and the headrest may each include one or more occupant support structures (shown in dashed lines) that can be controlled to transition from a compliant state to a rigid state and vice versa in order to adapt and reconfigure the vehicle seat to a body part of an occupant seated in the vehicle seat. DETAILED DESCRIPTION

[0022] The occupant support structure disclosed herein can be used to accommodate multiple different occupants by providing each occupant with the ability to selectively reconfigure and adapt a physical contour of the support structure to conform to their individual physical shape. The occupant support structure includes an adaptable and reconfigurable pad that can transition from a compliant state to a rigid state to selectively conform the pad to the contour of an occupant supported by the pad. For example, the pad can be held in a compliant state so that it can be formed into a negative impression of an occupant's body part, and then the pad can be controlled to transition from a compliant state to a rigid state to maintain a negative impression of the occupant.The pad can return to a compliant state, allowing it to be reconfigured and fitted to a different occupant or a different body part of the same occupant. This transition from a compliant to a rigid state can be achieved through a technique known as "layer clamping."

[0023] As used herein, the terms "rigid" and "flexible" are used in a relative sense. For example, when the terms rigid and flexible are used to describe the attributes of a material and / or the areas of a material, it is intended that the flexible material and / or the flexible areas are capable of bending and / or stretching in response to an applied force that is less than the force that would have to be exerted on the rigid material and / or the stiff areas to bend and / or stretch them. Both rigid and flexible materials and / or areas can be non-brittle and can bend and / or stretch in response to an applied force without fracture or fatigue.

[0024] Fig. 1 and Fig. Figure 2 shows a thin bubble 10, which is separated from a compliant state using a layer clamping technique ( Fig. 1) into a rigid state ( Fig. 2) can be transferred. The bubble 10 includes an outer wall 12 that defines an inner cavity 14. Several overlapping material layers 16 are enclosed within the cavity 14. The material layers 16 are positioned within the cavity 14 such that opposing surfaces of adjacent material layers 16 are in direct contact with each other. In the Fig. 1 and Fig. 2, the material layers 16 are aligned one above the other. In other embodiments, however, the material layers 16 can be offset or staggered relative to each other.

[0025] The cavity 14 is connected to a passage 18 via an opening 20 in the outer wall 12 of the bladder 10. A fluid (e.g., air) can be added to or drained from the cavity 14 via the opening 20 to increase or decrease the pressure within the cavity 14. For example, fluid can be drained from the cavity 14 to create a vacuum inside the cavity 14, and fluid can be added to the cavity 14 to increase the pressure inside the cavity 14 and / or to equalize the pressure inside the cavity 14 with the pressure outside the cavity 14 (at an outer surface of the bladder 10). In a mold, a vacuum pump and draining system 22 can be used to drain fluid from the cavity 14 via the passage 18 to create a vacuum inside the cavity 14.

[0026] The bladder 10 and the material layers 16 can transition from a flexible state to a rigid state and vice versa by creating a pressure difference across the outer wall 12 of the bladder 10. Fig. 1. In this case, the pressure inside the bladder 10 (within the cavity 14) is generally equal to the pressure outside the bladder 10 (outside the cavity 14), and the bladder 10 is in a compliant state. For example, the pressure inside the bladder 10 may be exactly the same as the pressure outside the bladder 10, or the pressure inside the bladder 10 may be within ± 5% of the pressure outside the bladder 10. In one form, the pressure inside and outside the bladder 10 may generally be equal to atmospheric pressure. In this compliant state, the overlapping material layers 16 can move relative to each other (for example, by sliding or shearing against each other) and can deform relatively easily in response to an applied force or external load.

[0027] In Fig. 2. The pressure inside bubble 10 (inside cavity 14) is lower than the pressure outside bubble 10 (outside cavity 14), and bubble 10 is in a rigid state. For example, the pressure inside bubble 10 can be 10 times lower than the pressure outside bubble 10. In one form, the pressure inside bubble 10 can be lower than atmospheric pressure, and the pressure outside bubble 10 can be equal to atmospheric pressure. As in Fig. As shown in Figure 2, in this rigid state the overlapping material layers 16 are pressed against each other by the outer wall 12 of the bladder 10. This increases the friction between the material layers 16 and significantly reduces their ability to move relative to each other (for example, by sliding or shearing past one another), so that the material layers 16 are "jammed" and the stiffness of the material layers 16 and the bladder 10 is increased. The degree of stiffness imparted to the material layers 16 and the bladder 10 can be adjusted by controlling the number of material layers 16, the area of ​​the opposing surfaces of the material layers 16, the frictional properties of the material layers 16, and / or the pressure differential across the outer wall 12 of the bladder 10.

[0028] When the bladder 10 is in a compliant state, the bladder 10 and the material layers 16 can be deformed or shaped into a desired configuration, for example, by applying an external load. Once the desired configuration is achieved, fluid can be emptied from the cavity 14 to transfer the bladder 10 and the material layers 16 into a rigid state and to "lock" the bladder 10 and the material layers 16 in the desired configuration. While the bladder 10 and the material layers 16 are in a rigid state, they can maintain the desired configuration even if the applied external load is removed, as long as the pressure inside the cavity 14 is lower than the pressure outside the bladder 10.Fluid can be actively or passively added to the cavity 14 to equalize the pressure across the outer wall 12 of the bladder 10, in order to return the bladder 10 and the material layers 16 to a compliant state and to their original configuration.

[0029] The bladder 10 can have a uniform, one-piece construction and can be made of any suitable deformable, stretchable, elastic, waterproof, and airtight material. For example, the bladder 10 can be appropriately manufactured from an elastomer such as natural or synthetic rubber.

[0030] The overlapping material layers 16 can be made of thin, solid, porous or non-porous flexible materials that can generate a sufficient degree of friction between the opposing surfaces of the material layers 16 when the material layers 16 are compressed against each other, such that relative movement between the material layers 16 (e.g., shearing of the material layers 16) is prevented. Some examples of suitable materials for the overlapping material layers 16 include: bonded networks of woven or non-woven synthetic or natural fibers, porous or non-porous amorphous elastic polymers (i.e., elastomers), e.g., natural or synthetic rubbers, and thermoplastics, such as polyurethane foam.

[0031] In some embodiments, the overlapping material layers 16 can comprise alternating first and second material layers 24, 26, wherein the first material layers 24 have a different material composition and / or configuration than the second material layers 26. For example, the first material layers 24 can comprise a rigid material and the second material layers 26 can comprise a flexible material. Additionally or alternatively, the first and second material layers 24, 26 can have different material compositions configured to come together to provide an appropriate degree of friction between the material layers 24, 26, for example, to prevent shearing of the material layers 24, 26. In one form, the first material layers 24 can have relatively smooth surfaces and the second material layers 26 can have relatively rough or textured surfaces.In one form, the first material layers 24 can comprise a porous material and the second material layers 26 can comprise a non-porous material. Some examples of suitable porous materials include: bonded networks of woven or non-woven synthetic or natural fibers and elastomeric foams. Some examples of suitable non-porous materials include: non-porous elastomers and rigid plastics.

[0032] The first and / or second material layer 24, 26 can comprise a continuous material layer or a discontinuous material layer with a variety of perforations or cavities formed therein. In one form, the first and / or the second material layer 24, 26 can comprise a continuous layer of a composite material consisting of patches or areas of different types of material. For example, the first and / or the second material layer 24, 26 can comprise a variety of interconnected rigid and compliant areas. The compliant areas can provide the material layers 24, 26 with the ability to flex and / or stretch when an external load is applied, so that the material layers 24, 26 can be planar or non-planar and conform to complex, curved, or non-planar surfaces.The compliant regions can also allow the rigid regions to move independently of each other while remaining physically connected and in place within the material layers 24, 26. When the bubble 10 is in a compliant state, the rigid regions and / or the compliant regions can comprise planar structures with a variety of different shapes, e.g., circular, elliptical, rectangular, square, triangular, hexagonal, or irregular. The rigid regions and / or the compliant regions can be arranged within the material layers 24, 26 in a regular (e.g., patterned) or stochastic manner.

[0033] In one mold, the first and / or second material layer 24, 26 can comprise a continuous material layer that includes several rigid regions physically connected to one another by a compliant matrix. The rigid regions can be coupled to the compliant matrix, for example, by being partially or completely physically enclosed within the matrix or by being coupled to a major surface of the flexible matrix. In one mold, the first and / or second material layer 24, 26 can be produced by bonding a plurality of rigid elements to a major surface of a compliant membrane.In another form, the first and / or the second material layer 24, 26 can be made from a thin elastic polymer film having several rigid areas that are physically connected to each other by a compliant matrix, and wherein the rigid areas in the film can be formed by increasing the crosslinking density of the polymer in these areas.

[0034] With current reference to Fig. Figure 3 shows a top view of a section of a thin layer of material 116 located in the bubble 10 of Fig. 1 according to one or more embodiments of the present disclosure. As shown, the material layer 116 comprises a network of rigid islands 128 separated from one another by cavities 130 and connected to one another by a plurality of flexible bridges 132. The bridges 132 can give the material layer 116 the ability to bend and / or stretch when an external load is applied, so that the material layer 116 can be easily modeled or shaped into a desired configuration. In addition, the bridges 132 can allow the islands 128 to move independently of one another while remaining physically connected and in place within the material layer 116.

[0035] Simultaneously, the rigid islands 128 can endow the material layer 116 with sufficient elasticity such that, when the material layer 116 is compressed against or between one or more other material layers, a sufficient degree of friction can be generated between the opposing surfaces of the layers to prevent movement of the layers relative to one another. In some embodiments, the bridges 132 can be configured to prestress the islands 128 relative to one another and to resist increased separation between the islands 128 in response to the application of an external load. Each of the flexible bridges 132 can extend between two of the rigid islands 128 and can follow a straight, curvilinear, bent, undulating, or serpentine path between the islands 128.

[0036] With current reference to Fig. Figure 4 shows a top view of another section of a thin layer of material 216 located in bubble 10 of Fig. 1 according to one or more embodiments of the present disclosure. The material layer 216 is in many respects the one described in Fig. 3, depicted material layer 116 is similar, and a description of the common features need not be repeated here. As in Fig. As shown in Figure 4, the material layer 216 comprises a network of rigid islands 228, separated from one another by cavities 230 and connected to each other by a multitude of flexible bridges 232. The bridges 232 can impart to the material layer 216 the ability to bend and / or stretch when an external load is applied, so that the material layer 216 can be easily modeled or shaped into a desired configuration. At the same time, the islands 228 can endow the material layer 216 with sufficient elasticity so that, when the material layer 216 is compressed against or between one or more other material layers, a sufficient degree of friction can be generated between the opposing surfaces of the layers to prevent movement of the layers relative to each other.Each of the yielding bridges 232 can extend between two of the rigid islands 228 and can follow a straight, curvilinear, curved, undulating or serpentine path between the islands 228.

[0037] In the Fig. Figure 4 shows that the islands 128, 228 are physically separated from each other by cavities 130, 230 in the material layers 116, 216. In other embodiments, however, the material layers 116, 216 can be continuous and free of cavities. In this case, the islands 128, 228 can be connected to each other by a single flexible bridge, for example, by a plate of flexible material (not shown).

[0038] One or more of the material layers 116, 216 can be used in combination with one or more different material layers to create a stack of overlapping material layers (not shown) that can be fitted into a bubble 10 to perform a layer interlocking technique. In a mold, the stack of overlapping material layers can contain alternating first and second layers, the first layers having the structure of material layer 116, which is described in Fig. Figure 3 shows that the second layers comprise continuous layers of a physically and chemically homogeneous compliant material. In another form, the stack of overlapping material layers can contain alternating first and second layers, the first layers having the structure of material layer 216 shown in Figure 3. Fig. 4 is shown and the second layers comprise continuous layers of a physically and chemically homogeneous compliant material.

[0039] Fig. Figure 5 shows an occupant support structure 300 according to one or more embodiments of the present disclosure. The occupant support structure 300 comprises a base 334, a reconfigurable cushion 336 supported by the base 334, and one or more prestressing elements 338 extending between the cushion 336 and the base 334. The base 334 can be configured to couple the occupant support structure 300 to a component of a vehicle (not shown). The reconfigurable cushion 336 is adapted to support one or more body parts of an occupant 340 of the vehicle and includes a bladder 310, an elastomeric pad 342 lying over the bladder 310, a cover 344 lying over the pad 342 and the bladder 310, and an occupant support surface 346 defined by an outer surface of the cover 344.

[0040] The bladder 310 extends beneath the occupant support surface 346 of the cushion 336 and is designed to selectively deflect the cushion 336 from a compliant state to a rigid state and vice versa, in order to adapt the cushion 336 to a contour of the occupant 340 of the vehicle and subsequently to reconfigure the cushion 336 to adapt to a different contour of the same or a different occupant 340 of the vehicle. The bladder 310 is in many respects the Fig. 1 and Fig. The bladder 310 is similar to the bladder 10 shown in Figure 2 and may embody some or all of its features. A description of common features between bladders 10 and 310 is not repeated here. The bladder 310 comprises an outer wall 312 that defines an inner cavity 314 extending beneath the occupant support surface 346 of the cushion 336. Two or more layers of material 316 are enclosed within the cavity 314 and are arranged such that the layers of material 316 overlap at least partially. Furthermore, the overlapping layers of material 316 may be positioned within the cavity 314 such that opposing surfaces of adjacent layers of material 316 are in direct contact with each other. Fig. 5 the material layers 316 are aligned one above the other; in other embodiments, however, the material layers 316 can be offset or stepped relative to each other.

[0041] The cavity 314 is in fluid communication with a passage 318 via an opening 320 in the outer wall 312 of the bladder 310. In the Fig. In the embodiment shown in Figure 5, the opening 320 is arranged in a side section of the bladder 10. In other embodiments, however, the opening 320 may be located in a different, suitably concealed or separate position. For example, the opening 320 may be arranged in a bottom section of the bladder 310, facing the base 334. A fluid (e.g., air) may be added to or drained from the cavity 314 via the opening 320 to increase or decrease the pressure within the cavity 314. For example, fluid may be drained from the cavity 314 to create a subatmospheric pressure environment within the cavity 314, and fluid may be added to the cavity 314 to increase the pressure within the cavity 314 and / or to equalize the pressure within the cavity 314 with the pressure outside the cavity 314 (outside the bladder 10).In one configuration, a vacuum pump and draining system (not shown) can be used to drain fluid from cavity 314 through passage 318 to create a negative pressure environment inside cavity 314.

[0042] The overlapping material layers 316 can be made of thin, rigid, porous, or non-porous flexible materials that can generate a sufficient degree of friction between the opposing surfaces of the material layers 316 when the material layers 316 are compressed against each other, thus preventing relative movement between the material layers 316 (e.g., shearing of the material layers 316). The number, size, elastic, and frictional properties of the overlapping material layers 316 can be selected to impart a suitable degree of stiffness to the pad 336 when the pad 336 is in a rigid state. The overlapping material layers 316 can suitably include one or more of the same materials as the material layers 16, 24, 26.

[0043] In some embodiments, the material layers 316 can comprise alternating first and second layers, wherein the first layers have a different material composition and / or configuration than the second layers. For example, the first layers can comprise a rigid material and the second layers can comprise a flexible material. Additionally or alternatively, the first and second layers can have different material compositions configured to come together to provide an appropriate amount of friction between the material layers 316, for example, to prevent shearing of the material layers 316. In one embodiment, the first layers can have relatively smooth surfaces and the second layers can have relatively rough or textured surfaces.In one embodiment, the first layers can comprise a porous material and the second layers can comprise a non-porous material. The first and / or second layers can comprise a continuous material layer or a discontinuous material layer with a plurality of perforations or cavities formed therein. In some embodiments, the material layers 316 can comprise alternating first and second layers, wherein the first layers comprise continuous or discontinuous layers of a composite material and the second layers comprise continuous layers of a physically and chemically homogeneous material. In some embodiments, the material layers 316 can be designed such that certain regions of one or more of the material layers 316, when in a rigid state, deform, preferably under a lower applied external load, than other regions.

[0044] In some embodiments, one or more of the material layers 316 can comprise a continuous layer of a composite material consisting of patches or regions of different types of material. For example, one or more of the material layers 316 can be a composite material comprising a variety of physically connected rigid regions and compliant regions. The compliant regions can provide the material layers 316 with the ability to flex and / or stretch when an external load is applied, so that the material layers 316 can be planar or non-planar and conform to complex, curved, or non-planar surfaces. The compliant regions can allow the rigid regions to move independently of one another while remaining physically connected and in place within the material layers 316.When the bladder 310 is in a compliant state, the rigid regions and / or the compliant regions can comprise planar structures with a variety of different shapes, e.g., circular, elliptical, rectangular, square, triangular, hexagonal, or irregular. The rigid regions and / or the compliant regions can be arranged within the material layers 316 in a regular (e.g., patterned) or stochastic manner.

[0045] In a mold, one or more of the material layers 316 can comprise a continuous layer of a composite material comprising a plurality of rigid regions physically connected to one another by a compliant matrix. The rigid regions can be coupled to the compliant matrix, for example, by being partially or completely physically enclosed within the matrix or by being coupled to a major surface of the flexible matrix. In a mold, one or more of the material layers 316 can be formed by bonding a plurality of rigid elements to a major surface of a compliant membrane.In another form, one or more of the material layers 316 can be made from a thin elastic polymer film having several rigid areas that are physically connected to each other by a compliant matrix, wherein the rigid areas in the film can be formed by increasing the crosslinking density of the polymer in these areas.

[0046] Like the in Fig. 3 and Fig. In the material layers 116 and 216 shown in Figure 4, one or more of the material layers 316 can comprise a composite material that includes a network of rigid regions (or islands) connected by one or more flexible regions (or bridges). In one form, one or more of the material layers 316 can comprise a network of rigid islands separated by cavities and connected by a plurality of flexible bridges. For example, one or more of the material layers 316 can consist of material layer 116 or material layer 216, which are arranged in Fig. 3 and Fig. 4 are shown.

[0047] The elastomeric pad 342 extends over the bladder 310 and is coupled between the bladder 310 and the cover 344. The pad 342 can be designed to support the occupant 340 and to provide a soft, comfortable feel to the occupant 340, who is supported on the cushion 336. Some examples of suitable materials for the elastomeric pad 342 include polyurethane foam.

[0048] The cover 344 is coupled to the pad 342 and can be designed to cover the elastomeric pad 342 and the bladder 310 to protect the pad 342 and the bladder 310 and / or to give the cushion 336 a desirable look and feel. Some examples of suitable materials for the cover 344 include vinyl, woven or nonwoven fabric (e.g., cotton, polyester, or nylon), leather, or a combination thereof. In one form, the cover 344 may include a layer of fabric coated on one or both sides with a layer of an elastomer (e.g., neoprene or silicone).

[0049] The one or more pretensioning elements 338 are designed to pretension the pad 336 in a direction away from the base 334 and to resist movement of the pad 336 in a direction towards the base 334 in response to an external load exerted by the occupant 340 on the occupant support surface 346 of the pad 336. Additionally, the one or more pretensioning elements 338 can be designed to provide a desired contour to the occupant support surface 346 of the pad 336 when the occupant 340 is supported or unsupported on the pad 336. The one or more pretensioning elements 338 can also be designed to help position the occupant 340 in a desired position and orientation on the pad 336.Thus, one or more pretensioning elements 338 can be controlled to help distribute the weight of the occupant 340 evenly across the occupant support surface 346 of the cushion 336. Some examples of suitable pretensioning elements 338 for use in the occupant support structure 300 include springs, expandable (e.g., inflatable) containers, or a combination thereof.

[0050] In some embodiments, one or more preload elements 338 can be reconfigurable and can be adapted to change their size and / or shape in response to a vehicle command that can be initiated by the occupant 340. For example, as in Fig. As shown in Figure 5, the one or more pretensioning elements 338 may initially have a first size and shape, but may increase in size in response to a vehicle command. The ability of the pretensioning elements 338 to change size and / or shape, individually or collectively, may allow the occupant 340 to adjust or tailor the contour, orientation, and / or height of the occupant support surface 346 of the cushion 336 to improve the fit, support, and / or comfort of the cushion 336 for the occupant 340.

[0051] The cushion 336 can be controlled to conform to one contour of the vehicle occupant 340 and subsequently to another contour of the same or a different vehicle occupant 340 by selectively controlling a pressure state across the outer wall 312 of the bladder 310. Initially, the pressure inside the bladder 310 (within the cavity 314) can be controlled to be essentially the same as the pressure outside the bladder 310 (outside the cavity 314), for example, by allowing the pressure inside the bladder 310 to equalize with the pressure outside the bladder 310. When a generally equal pressure state across the outer wall 312 of the bladder 310 is established (i.e.,(If the pressure inside the bladder 310 is essentially the same as the pressure outside the bladder 310), the bladder 310 is in a compliant state and the pad 336 (including the bladder 310, the support 342, and the cover 344) can be deformed or shaped into a desired configuration, for example, by applying an external load. Thus, the occupant 340 can be positioned on the occupant support surface 346 of the pad 336 (for example, by sitting on it), such that a body part of the occupant 340 presses against the occupant support surface 346 and exerts sufficient force on it to deform the pad 336 and adapt the occupant support surface 346 of the pad 336 to a contour of the body part of the occupant 340.

[0052] While the occupant 340 is positioned on the occupant support surface 346 of the cushion 336, a pressure differential can be established across the outer wall 312 of the bladder 310, such that the pressure inside the bladder 310 is lower than the pressure outside the bladder 310. The pressure inside the bladder 310 (within the cavity 314) can be reduced, for example, by emptying fluid (e.g., air) from the cavity 314 through the opening 320 in the outer wall 312 of the bladder 310. When a negative pressure condition arises over the bladder 310 (i.e., when the pressure inside the bladder 310 is less than the pressure outside the bladder 310), the bladder 310 is in a rigid state and the pad 336 (including the bladder 310, support 342 and cover 344) cannot simply be deformed in response to an applied external load on the occupant support surface 346.Furthermore, when the bladder 310 is in a rigid state, the pad 336 does not change its shape or return to an initial configuration, even if a previously applied external load is removed. Once the bladder 310 has sufficiently transitioned from a compliant to a rigid state, the occupant 340 can move away from the occupant support surface 346 of the pad 336, and the occupant support surface 346 retains a rigid contour of the occupant 340's body part.

[0053] The occupant support surface 346 of the cushion 336 can be allowed to return to its initial configuration by enabling the pressure inside the bladder 310 to equalize with the pressure outside the bladder 310. Subsequently, the occupant support surface 346 of the cushion 336 can be reconfigured to a different contour of the same or a different occupant 340 by positioning the same or a different occupant 340 on the occupant support surface 346 of the cushion 336 such that a body part of the occupant 340 presses against it and exerts a force on the occupant support surface 346 sufficient to deform the cushion 336 and adapt the occupant support surface 346 of the cushion 336 to the contour of the body part of the occupant 340.

[0054] Accordingly, the occupant support structure 300 of the vehicle disclosed herein can be used to personalize or adapt one or more support structures of a vehicle in order to optimize fit, support, weight distribution, comfort and / or safety of the same occupant 340 or of another occupant of the vehicle.

[0055] Fig. Figure 6 shows an exemplary embodiment of a seat 400 for an occupant of a vehicle (not shown) according to one or more embodiments of the present disclosure. For example, the seat 400 may comprise a driver's seat, a passenger seat, a child seat, or a booster seat. The seat 400 includes a seat surface 450 comprising a pair of side seat surface cushions 452, a seat backrest 454 with a pair of side seat backrest cushions 456, and a headrest 458. The occupant support structure 300 of the vehicle, comprising the bladder 310 (and optionally the base 334, the one or more pretensioning elements 338, the elastomeric support 342, and the cover 344), may be contained in or integrated into one or more zones of the seat 400. For example, one or more bubbles 310' may be contained or integrated into the seat surface 450 and / or one or both of the side seat surface cushions 452.Additionally or alternatively, one or more bladders 310" may be contained in or integrated into the seat backrest 454 and / or one or both of the side seat backrest cushions 456. Additionally or alternatively, one or more bladders 310''' may be contained in or integrated into the headrest 458. The inclusion or integration of one or more of the bladders 310', 310'', 310''' into the seat 400 may enable one or more zones of the seat 400 to adapt individually or collectively to a body part of an occupant seated on the seat 400 by controlling the bladders 310 for the selective transition from a yielding state to a rigid state and vice versa by selectively controlling a pressure state across the outer walls of the bladders 310', 310'', 310''', as described in more detail above with reference to the . Fig. 1, Fig. 2 and Fig.5 was discussed. In embodiments in which the seat 400 comprises a child seat or booster seat, the bladders 310', 310'' and / or 310'' can enable different zones of the seat 400 to be individually or collectively periodically reconfigured to adapt to a body part of an occupant sitting on the seat 400, so that the seat 400 can be tailored to adapt to the safety and comfort of the occupant, to support the occupant and / or to maintain this as the occupant grows. Although not shown in the drawings, the vehicle's occupant support structure 300, which includes the bladder 310 (and optionally the base 334, the one or more prestressing elements 338, the elastomeric support 342 and the cover 344), may additionally or alternatively be included in one or more other support structures of a vehicle, for example in an armrest or footrest for an occupant of the vehicle.

Claims

[1] Occupant support structure (300), comprising: a base (334); a reconfigurable cushion (336) supported by the base (334) and adapted to support a body part of an occupant (340), wherein the reconfigurable cushion (336) includes an occupant support surface (346) and a bladder (310) with an outer wall (312) defining an inner cavity (314) beneath the occupant support surface (346) and two or more overlapping material layers (316) arranged in the cavity (314), and one or more prestressing elements (338) arranged between the base (334) and the reconfigurable cushion (336), wherein the one or more prestressing elements (338) are configured to prestress the cushion (336) away from the base and to resist movement of the cushion (336) towards the base in response to an external load applied by an occupant (340) to the occupant support surface (346) of the cushion (336), wherein the overlapping material layers (316) are designed to selectively transition from a compliant state to a rigid state and vice versa by selectively controlling a pressure state across the outer wall (312) of the bladder (310) or to adapt the occupant support surface (346) of the cushion (336) to a contour of a body part of an occupant (340) that is supported by the cushion (336), wherein, when atmospheric pressure is created across the outer wall (312) of the bladder (310), the overlapping material layers (316) are adapted to exhibit a compliant state and to deform in response to an external load exerted by an occupant (340) on the occupant support surface (346) of the cushion (336), and wherein, when a negative pressure condition is created across the outer wall (312) of the bladder (310), the overlapping material layers (316) are adapted to exhibit the rigid state and to prevent deformation of the occupant support surface (346) in response to the application or removal of an external load to the occupant support surface (346) of the cushion (336). [2] Occupant support structure (300) according to claim 1, wherein the overlapping material layers (316) are positioned within the cavity (314) such that opposing surfaces of adjacent material layers (316) are in direct contact with each other, and wherein the overlapping material layers (316) are designed such that when a negative pressure condition is created over the outer wall (312) of the bladder (310), friction is generated between the opposing surfaces of the material layers (316) so that shearing of the material layers is prevented. [3] Occupant support structure (300) according to claim 1, wherein at least one of the overlapping material layers (316) comprises a composite material comprising a network of rigid areas physically connected to each other by one or more compliant areas, and wherein the compliant areas are designed to prestress the rigid areas towards each other and to resist relative movement of the rigid areas in response to an applied external load. [4] Occupant support structure (300) according to claim 3, wherein at least one of the overlapping material layers (316) comprises a continuous layer of a physically and chemically homogeneous material. [5] Occupant support structure (300) according to claim 1, wherein the overlapping material layers (316) comprise alternating first and second layers, and wherein the first layers have a different material composition or configuration than the second layers. [6] Occupant support structure (300) according to claim 1, including a vacuum pump and a draining system for selectively creating a negative pressure condition within the cavity (314). [7] Occupant support structure (300) according to claim 1, wherein the reconfigurable cushion (336) comprises an elastomeric pad (342) that lies over the bladder (310) and a cover (344) that lies over the elastomeric pad (342), and wherein the occupant support area (346) is defined by the cover (344). [8] Occupant support structure (300) according to claim 1, wherein the reconfigurable cushion (336) comprises a seat backrest (454), a seat surface (450), an armrest, a footrest or a headrest (458) for an occupant (340) of a vehicle. [9] Method for adapting an occupant support structure, the method comprising the following steps: (a) Providing an occupant support structure (300) according to any one of the preceding claims 1 to 8; (b) Establishing an initial pressure state across the outer wall of the bladder so that the cushion has an initial configuration; (c) Positioning a first occupant in contact with the occupant support surface of the cushion so that a body part of the first occupant presses against the occupant support surface and adapts the occupant support surface to a contour of the body part of the first occupant; (d) Establishing a second pressure state across the outer wall of the bladder while the first occupant is in contact with the occupant support surface to engage frictionally with the overlapping material layers and to impart a predetermined stiffness to the cushion; and (e) Maintaining the second pressure state across the outer wall of the bladder so that the occupant support surface retains the contour of the first occupant's body part.

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