VEHICLE USE SUPPORT, INCLUDING AN UPPER HOOD MODULE

Abstract

A user support includes a canopy structure supported by a rear frame structure of the user support. The canopy structure may comprise a one-piece, homogeneous polymer structure formed by an additive process. The canopy structure may include solid structures and at least one porous lattice matrix integrally formed with the solid structures.

Description

FIELD OF DISCLOSUREThe present disclosure relates generally to a user support for vehicles, and more particularly to a support assembly having an upper hood module that may include one or more components having a porous mesh matrix.GENERAL STATE OF THE ARTVarious vehicle user supports have been developed. Such supports may be configured to support a user and / or passengers in a vehicle interior during operation of the vehicle.SUMMARY OF THE DISCLOSUREOne aspect of the present disclosure is a user support for vehicles. The user support includes a frame having a lower portion and a rear portion extending upwardly from the lower portion. The user support also includes a lower bolster secured to the lower portion of the frame. The lower pad has an upward facing surface. The user support includes a rear bolster secured to the rear portion of the frame. The rear cushion has a forwardly facing surface and an upper edge. The user support further includes an integral polymeric hood structure having a base secured to the rear frame structure and an upper hood structure extending upwardly beyond the upper edge of the upper rear frame structure. The integral polymeric hood structure may include an integral porous mesh matrix extending across the gaps between the elongated front and rear structures. The user support further includes a pad assembly positioned over the rear cushion. The deck assembly may include left and right deckers secured to the one-piece polymeric hood structure in a side-by-side configuration. Each overlay may comprise a forwardly facing resilient layer of material and a rear layer of material. Each overlay further includes a porous mesh matrix integrally formed with the forward facing elastic layer of material and with the back layer of material to form an integral homogeneous polymeric structure. The porous mesh matrix is disposed between the forward elastic layer of material and the back layer of material. The porous mesh matrix has a porous outer peripheral portion or shell which extends between the forwardly facing elastic layer of material and the rear layer of material whereby the porous outer shell is exposed and visible.• The elongated front and rear structure of each left and right outer structure may extend towards each other, thereby reducing a size of the gap between the elongated front and rear structures at the upper ends of the elongated front and rear structures.• The integral polymeric hood structure may comprise nylon or other suitable material and may be formed using an additive process.• The left and right supports may optionally comprise thermoplastic polyurethane.• Each of the left and right supports has a lower edge spaced from the upper edge of the upper pad to form a horizontally extending gap.• The upper hood structure may include an integral left and right outer structure, each of the left and right outer structures including an elongated front and rear structure extending toward each other, thereby reducing a size of the gap between the elongated front and rear structures at upper ends of the elongated front and rear structures.• The integral polymeric hood structure may include a forwardly opening pocket formed by a pocket structure integrally formed with upper ends of the left and right outer structures, and the user support may include a base having a pad disposed adjacent the forwardly opening pocket and a support structure connecting the base to the rear portion of the frame.• The left and right outer structures may extend upwardly and inwardly from the base towards each other.• The integral polymeric hood structure may include an integral porous mesh matrix extending across the gaps between the elongated front and rear structures, the integral porous mesh matrix having an exposed outer side that is visible.• Each of the elongated front and rear structures may comprise a porous mesh matrix and an impermeable outer layer extending around and encapsulating the porous mesh matrix.• The base of the one-piece polymeric hood structure may include a porous mesh matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous mesh matrix.• The porous mesh matrix of the base of the one-piece polymeric hood structure may extend horizontally over a lower portion of the base of the one-piece polymeric hood structure.• The user support may include a sound passageway having a first end configured to be operatively coupled to a sound source, whereby sound enters the first end of the sound passageway. The sound passageway has a second end with at least one opening formed in the one-piece polymeric hood structure whereby sound entering the first end exits the at least one opening, and wherein at least a portion of the passageway comprises a tubular structure integrally formed with the porous lattice structure of the one-piece polymeric hood structure.Another aspect of the present disclosure is an upper hood module for user supports for vehicles. The upper hood module includes an integral polymeric hood structure having a base configured to be secured to a rear frame structure of a user support and an upper hood structure over the base. The integral polymeric hood structure includes an outer layer and a porous mesh matrix integrally formed with the outer layer. The one-piece polymer hood structure includes a homogeneous polymer structure formed by an additive process from a first polymer having a first elasticity. The hood structure further includes at least one deck attached to the one-piece polymeric hood structure. The at least one overlay comprises a forward resilient layer of material, a back layer of material, a resilient porous mesh matrix integrally formed with the forward resilient layer of material and with the back layer of material, whereby the at least one overlay comprises an integral homogeneous structure, and wherein the porous mesh matrix is disposed between the forward resilient layer of material and the back layer of material. The at least one overlay comprises a homogeneous polymer structure formed by an additive process from a second polymer having a second elasticity, wherein the second elasticity is less than the first elasticity.• The porous mesh matrix of the at least one overlay may comprise a porous outer shell extending between the forwardly facing elastic layer of material and the rear layer of material whereby the porous outer shell is exposed and visible.• The at least one support may comprise left and right supports positioned side by side and the left and right supports may comprise thermoplastic polyurethane.• The at least one overlay may include a plurality of voids formed in the backsheet of material and the integral polymeric hood structure may include a plurality of protrusions positioned in the voids of the at least one overlay.• The base of the one-piece polymeric hood structure may include a porous mesh matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous mesh matrix, and the porous mesh matrix of the base of the one-piece polymeric hood structure may extend horizontally over a lower portion of the base of the one-piece polymeric hood structure.• The integral polymeric hood structure may include a central opening and first and second side openings, wherein the central opening and the first and second side openings may extend through the integral polymeric hood structure in a longitudinal direction across the at least one deck.Another aspect of the present disclosure is a method of manufacturing a user support for vehicles. The method includes providing a frame having a lower portion and an upright rear portion. The method further includes forming a homogeneous, one-piece polymeric hood structure using an additive process. The additive process includes forming an outer layer of polymeric material extending around at least a portion of a porous mesh matrix such that the outer layer of polymeric material is integrally formed with the porous mesh matrix. The method further includes attaching a resilient pad to a front side of the one-piece polymeric hood structure.• An additive process may be used to form the resilient pad from a material having greater elasticity than the polymeric material of the hood structure, and the at least one pad may include a resilient porous mesh matrix.• The method may include utilizing an additive process to form a sound pipe extending upwardly through the porous mesh matrix of the one-piece polymeric hood structure, wherein the sound pipe is integrally formed with the porous mesh matrix and forms an opening at a front side of the one-piece polymeric hood structure.These and other features, advantages and objects of the present disclosure will be better understood and understood by those skilled in the art by reference to the following description, claims and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGSIn the drawings, the following applies: FIG. 1 is a partially fragmentary perspective view of a user support for vehicles according to an aspect of the present disclosure; FIG. 2 is a perspective view of the user support of FIG. 1 ; FIG. 3 is an exploded perspective view of the user support of FIGS. 1 and 2 ; FIG. 4 is an enlarged, partially fragmentary, perspective view of a portion of the user support of FIG. 1 ; FIG. 5 is a cross-sectional view of the user support of FIG. 2 taken along line V-V; FIG. 6 is a cross-sectional view of the user support of FIG. 2 taken along line VI-VI; FIG. 7 is a cross-sectional view of the user support of FIG. 2 taken along line VII-VII; FIG. 8 is a schematic view of a vehicle including a user support according to another aspect of the present disclosure; and FIG. 9 is a fragmentary enlarged view of a portion of the user support of FIG. 8.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTSThe present application relates to U.S. Patent Application No. 18 / 541,739, entitled "A USER SUPPORT ASSEMBLY FOR VEHICLES" (assignee's serial number 84805943), filed on even date herewith, and U.S. Patent Application No. 18 / 541,851, entitled "VEHICLE USER SUPPORT INCLUDING FLEXIBLE LIGHTING FEATURES" (assignee's serial number 84805805), filed on even date herewith, the entire contents of which are incorporated herein by reference.Reference will now be made in detail to the present preferred embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. In the drawings, the same reference numerals are used to designate the same or similar parts where possible. In the drawings, the depicted structural elements are not to scale and certain components are exaggerated relative to the other components for emphasis and understanding.As used herein, the term "and / or," when used in a listing of two or more items, means that each of the listed items may be used individually or any combination of two or more of the listed items may be used. For example, when a composition is described as containing components A, B, and / or C, the composition may contain only A; only B; only C; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.In this specification, relational expressions such as first and second, upper and lower, and the like are used only to distinguish one entity or action from another entity or action without necessarily requiring or implying an 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 device that / she comprises a listing of items does not include only those items, but may include other items that are not expressly listed or inherent to such process, method, article, or device. An element preceded by "comprises / a / a... " does not exclude, without further limitations, the presence of additional identical elements in the process, method, article, or apparatus comprising the element / s.As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other sizes and properties are not accurate and need not be accurate, but may be approximately and / or greater or smaller, if desired, and may reflect tolerances, conversion factors, rounding off, measurement errors, and the like, and other factors known to those of ordinary skill in the art. When the term "about" is used to describe a value or an endpoint of a range, the disclosure should be understood to include the specific value or endpoint referred to. Regardless of whether a numerical value or an end point of a range includes "about" in the description, the numerical value or the end point of a range is intended to include two embodiments: one modified by "about" and one not modified by "about". It will be further understood that the endpoints of each of the ranges are significant with respect to both the other endpoint and independent of the other endpoint.The terms "substantial", "substantially" and variations thereof are intended to indicate in the present context that a described feature is equal to or approximately equal to a value or description. For example, a "substantially planar" surface is intended to mean that a surface is planar or approximately planar. Moreover, "substantially" is intended to mean that two values are equal or approximately equal. In some embodiments, "substantially" may refer to values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.As used herein, the terms "the," "the," or "a" or "an" mean "at least one(s)," and should not be limited to "only one(s)," unless expressly stated to the contrary. Thus, for example, reference to "a component" includes embodiments having two or more such components, unless the context clearly indicates otherwise.For purposes of description herein, the terms "top," "bottom," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof refer to the concepts in their orientation in FIG. 1, however, it should be understood that the concepts may assume various alternative orientations, unless expressly stated to the contrary. It is also to be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Thus, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.Referring to FIGS. 1-5, a seat or user support 1 is configured for use in a vehicle 2 or other suitable applications. The user support 1 includes a frame 3 (FIG. 3 ) having a lower portion 4 and a generally upright rear portion 5 extending upwardly from the lower portion 4. A lower pad 8 is fixed to the lower portion 4 of the frame 3. The lower bolster 8 includes an upward facing surface 9. the user support 1 further includes a rear bolster 10 that may be attached to the upper portion 5 of the frame 3. The rear cushion 10 has a forwardly facing surface 11 and an upper edge 12.The rear portion 5 of the frame 3 may include an upper rear frame structure 13 that extends upwardly beyond the upper edge 12 of the rear cushion 10. The upper rear frame structure 13 includes an upper edge 14 (FIG. 3 ).The user support 1 may further include an upper hood module, such as an integral polymeric hood structure 20, formed using an additive process (e.g., 3D printing). As discussed below, the hood structure 20 may include a porous mesh matrix 56 integrally formed with an outer shell or layer 54. The outer layer 54 may include a gap or opening 16 (FIGS. 2 and 5 ), whereby a portion of the porous mesh matrix 56 is exposed (visible). The integral polymeric hood structure 20 includes a base 22 secured to the upper rear frame structure 13 and an upper hood structure 24 extending upwardly beyond the upper edge 14 of the upper rear frame structure 13. The integral polymeric hood structure 20 may include an integrally formed pocket 42 (FIG. 5 ) that receives the upper rear frame structure 13 to secure the integral polymeric hood structure 20 to the frame 3. Mechanical fasteners or the like may be used to attach the integral polymeric hood structure 20 to the rear frame 5. The upper hood structure 24 may have a generally inverted V-shape formed by left and right outer structures 26A and 26B, respectively. The left and right outer structures 26A and 26B may extend upwardly and inwardly from the base 22. Each of the left and right outer structures 26A and 26B may include elongated front and rear structures 28A and 28B spaced apart from one another to form gaps 30. The integral polymeric hood structure 20 includes at least one integral porous mesh matrix 32 that extends between the elongated front and rear structures 28A and 28B across the gaps 30 (see also FIG. 7 ). Optionally, a pair of integral porous mesh matrices 32A, 32B (FIG. 7 ) may extend between the elongated front and rear structures 28A and 28B. The integral polymeric hood structure 20 further includes a forwardly opening pocket 34 formed by a pocket structure 35 integrally formed with the upper ends 36A and 36B of the left and right outer structures 26A and 26B.The user support 1 further includes a base 38 having a cushion 40 (e.g., foam). The pad 38 is disposed adjacent the forwardly opening pocket 34. The base 38 includes a support structure or structures 41 (FIG. 3 ) connected to the rear portion 5 of the frame 3. The pad 40 may optionally include an elastic porous mesh structure having an optional elastic outer layer integrally formed with the elastic porous mesh structure.The user support 1 may further include an upper deck assembly 44 including left and right shelves 44A, 44B, respectively, that are secured to the one-piece polymer hood structure 20 in a side-by-side configuration. Each overlay 44A, 44B includes a forward resilient layer 46 of material (see also FIG. 5 ), a back layer of material 48, and a porous mesh matrix 50 disposed between the resilient layer 46 and the layer of material 48 using an additive process (e.g., 3D printing) to form an integral, unitary, homogeneous structure. The porous mesh matrix 50 is preferably formed elastically and integrally with the elastic layer 46 and the layer of material 48. The porous mesh matrix 50 includes a porous outer shell 52 that extends between the elastic layer 46 and the layer of material 48 such that the porous outer shell 52 is exposed and visible. The outer shell 52 may comprise members of the porous mesh matrix that extend generally parallel to an outermost surface of the porous mesh matrix 50.The pads 44A and 44B may be formed from an elastic thermoplastic polyurethane (TPU) material using a multi-jet fusion (MJF) additive manufacturing process. The thickness of the layers 46 and 48 and the configuration of the porous mesh matrix 50 may be selected to provide a desired level of cushioning (elasticity) in the upper rear region of a user. The pads 44A and 44B may optionally be configured to have greater elasticity than the hood structure 20.The pads 44A and 44B may be formed with pocket halves 58A and 58B, respectively, that form a pocket 58 (FIG. 5 ), whereby a detection sign 60 may be positioned within the pocket 58. Generally, the pocket halves 58A and 58B may be integrally formed in the front layers 46 of the liners 44A and 44B, respectively.Referring to FIGS. 3 and 4, the base 22 of the hood 20 may include a plurality of forwardly extending protrusions 66 closely received in pockets 63 of the shelves 44A and 44B to thereby locate and secure the shelves to the hood 20. The supports 44A and 44B may also be secured to the hood 20 using mechanical fasteners (e.g., integrally formed snap connectors), threaded fasteners, adhesives, or other suitable arrangement. Thus, the protrusions 66 and the pockets 63 are merely an example of a suitable connection arrangement.The hood 20 may include a central opening 17 and side openings 18A and 18B that pass through the hood 20, and the elongated front and rear structures 28A and 28B may optionally include forward facing openings 64 that receive audio speakers 66. Covers 68 may be attached to the hood 20 over the speaker 66. The covers 68 may include a porous layer 69, allowing sound from the speaker 66 to pass through the porous layer 69. The covers 68 may be formed by an additive process and may include, for example, TPU rubber formed by a multi-jet fusion (MJF) process or nylon formed using a selective laser sintering (SLS) process.Referring to FIGS. 5-7, the integral polymeric hood structure 20 may include an outer skin or layer 54 and an integrally formed porous mesh matrix 56. The integral polymeric hood structure 20 may be fabricated using an additive process, wherein the outer layer 54 and the porous mesh matrix 56 are integrally formed, whereby the integral polymeric hood structure 20 comprises an integrally homogeneous structure. In a preferred embodiment, the integral polymeric hood structure 20 is fabricated using selective laser sintering (SLS) using a nylon polymeric material. The thickness and shape of the skin or layer 54 and the configuration and thickness of the porous mesh matrix 56 may be varied as desired to provide the required stiffness and / or other overall structural features of the one-piece polymeric hood structure 20. The outer layer 54 may be substantially continuous and impermeable (except, for example, at gap 16) such that the porous mesh matrix 56 is disposed in an integral cavity or space within the outer layer 54. It should be understood that the porous mesh matrix 56 may extend through the entire space within the outer layer 54 or only portions thereof. For example, the outer layer 54 may provide sufficient strength and / or rigidity in some areas such that the porous mesh matrix 56 is not required in these areas of the hood structure 20.Referring to FIGS. 5 and 6, the base 22 of the hood structure 20 may include an integral inner layer or wall 54A that engages the upper rear frame structure to support the hood structure 20 on the frame 3. Mechanical fasteners or the like (not shown) may also be used to attach the hood structure 20 to the frame 3.Referring to FIG. 7, the elongated front and rear structures 28A and 28B may include a porous mesh matrix 56 and an integrally formed outer layer 54 that extends around and encapsulates the porous mesh matrix 56. As discussed above, the hood structure 20 may optionally include at least some interior spaces or voids that do not include a porous mesh matrix 56. For example, all or a portion of the space within the outer layer 54 of the front and / or rear structures 28A and 28B may optionally include a space free of internal structures, such as a porous mesh matrix 56.Referring to FIGS. 8 and 9, the user support 1 may include a sound enhancement system 80 that includes an audio passageway (sound passageway) 70 operatively coupled to one or more sound sources 72A and 72B. The passageway 70 may include one or more sections in the form of tubes 73A and 73B connected at a junction 74 to an upwardly extending portion 75. An upper portion 76 (FIG. 9 ) of the passageway 70 includes a layer 77 of material in the form of a tubular structure integrally formed with the mesh 56, whereby sound 78 travels through the upper portion 76 of the passageway 70 and exits at an upper opening 79. The user support 1 may include two or more apertures 79, which may be operatively connected (fluidly connected) to separate branches of a single passage 70, the branches extending from a "Y" connection in the passage 70. Alternatively, two or more apertures 79 may be operatively connected to two or more apertures 70. The opening 79 may be formed in a similar manner to and provided at a similar location to the openings 64 (FIG. 3 ) to allow the speaker 66 and porous covers or grille shutters 82 to be positioned over the opening / openings 79.The audio passageway 70 is preferably a continuous passageway that causes sound from one or more sources 72A, 72B, etc. to enter a first end of the tube 73A and / or 73B and travel through the passageways 70 to the opening or openings 79 and exit the audio passageway 70 adjacent a user. Examples of sound sources 72A and 72B include engine noise or other desirable noise as disclosed in U.S. Pat. No. 11 280 303, the entire contents of which are incorporated by reference. For example, source 72A may be located under a hood of vehicle 2 and may include an intake system of a combustion system and source 72B may include an exhaust system of an internal combustion engine. Generally, a single source 72A or 72B may be utilized. It should be appreciated that the passageways 70 and sound sources 72A and 72B of FIG. 8 are schematic in nature and the passageways 70 may have a wide range of configurations and the sound sources 72A, 72B, etc. may include a wide variety of sound sources.It is to be understood that variations and modifications may be made to the above structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims expressly state otherwise by their language.According to the present invention, there is provided a user support for vehicles, comprising: a frame having a lower portion and a rear portion extending upwardly from the lower portion, the rear portion of the frame including an upper rear frame structure having an upper edge; a lower pad secured to the lower portion of the frame, the lower pad having an upwardly facing surface; a rear pad secured to the rear portion of the frame, the rear pad having a forwardly facing surface and an upper edge; an integral polymeric hood structure having a base secured to the upper rear frame structure and an upper hood structure extending upwardly above the upper edge of the upper rear frame structure; and an upper pad assembly attached to the one-piece polymeric hood structure whereby the upper pad assembly is positioned over the upper edge of the rear pad, the upper pad assembly including at least one pad having a forwardly facing elastic layer of material, a rear layer of material, and an elastic porous mesh matrix integrally formed with the forwardly facing elastic layer of material and with the rear layer of material to form an one-piece homogeneous polymeric structure, the porous mesh matrix being disposed between the forwardly facing elastic layer of material and the rear layer of material, the elastic porous mesh matrix having an integrally porous outer shell extending between the forwardly facing elastic layer of material and the rear layer of material whereby the porous outer shell is exposed and visible.According to one embodiment: the integral polymeric hood structure is formed from nylon using an additive process whereby the integral polymeric hood structure is homogeneous.According to an embodiment: the at least one overlay comprises left and right overlays arranged in a side-by-side configuration, wherein the left and right overlays are formed from thermoplastic polyurethane using an additive process.According to one embodiment: each of the left and right shelves has a lower edge spaced from the upper edge of the rear cushion to form a horizontally extending gap.According to one embodiment: the upper hood structure includes integral left and right outer structures each including elongate front and rear structures extending toward each other, thereby reducing a size of the gap between the elongate front and rear structures at upper ends of the elongate front and rear structures.According to one embodiment: the integral polymeric hood structure includes a forwardly opening pocket formed by a pocket structure integrally formed with upper ends of the left and right outer structures; and including: a base having a pad disposed adjacent the forwardly opening pocket; and a support structure connecting the base to the rear portion of the frame.According to an embodiment: the left and right outer structures extend upwardly and inwardly from the base towards each other.According to one embodiment: the integral polymeric hood structure includes an integral porous mesh matrix extending across the gaps between the elongated front and rear structures, the integral porous mesh matrix having an exposed outer side between the elongated front and rear structures that is visible.According to one embodiment: each of the elongated front and back structures comprises a porous mesh matrix and an impermeable outer layer extending around and encapsulating the porous mesh matrix.According to one embodiment: the base of the one-piece polymeric hood structure includes a porous mesh matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous mesh matrix, wherein the porous mesh matrix of the base of the one-piece polymeric hood structure extends horizontally over a bottom portion of the base of the one-piece polymeric hood structure.According to one embodiment, the invention is further characterized by: a sound passageway having a first end configured to be operatively coupled to a sound source whereby sound enters the first end of the sound passageway, wherein the sound passageway has a second end with at least one opening formed in the one-piece polymeric hood structure whereby sound entering the first end exits the at least one opening, and wherein at least a portion of the passageway comprises a tubular structure formed integrally with the porous lattice structure of the one-piece polymeric hood structure.According to the present invention, there is provided an upper hood module for user supports for vehicles, comprising: an integral polymeric hood structure having a base configured to be attached to a rear frame structure of a user support, and an upper hood structure over the base, wherein the integral polymeric hood structure includes an outer layer and a porous mesh matrix integrally formed with the outer layer, and wherein the integral polymeric hood structure includes a homogeneous polymeric structure formed from a first polymer having a first elasticity by an additive process; and at least one overlay attached to the one-piece polymeric hood structure, the at least one overlay having a forward elastic layer of material, a back layer of material, and an elastic porous mesh matrix integrally formed with the forward elastic layer of material and with the back layer of material, whereby the at least one overlay comprises an one-piece homogeneous structure, and wherein the porous mesh matrix is disposed between the forward elastic layer of material and the back layer of material, wherein the at least one overlay comprises a homogeneous polymeric structure formed by an additive process from a second polymer having a second elasticity, wherein the second elasticity is less than the first elasticity.According to one embodiment: the porous mesh matrix of the at least one overlay comprises a porous outer shell extending between the forwardly facing elastic layer of material and the rear layer of material whereby the porous outer shell is exposed and visible.According to one embodiment: the at least one overlay comprises left and right overlays positioned side by side; and the left and right overlays comprise thermoplastic polyurethane.According to one embodiment: the at least one overlay includes a plurality of cavities formed in the backsheet of material; and the unitary polymeric hood structure includes a plurality of protrusions positioned in the cavities of the at least one overlay.According to one embodiment: the base of the one-piece polymeric hood structure includes a porous mesh matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous mesh matrix, wherein the porous mesh matrix of the base of the one-piece polymeric hood structure extends horizontally over a bottom portion of the base of the one-piece polymeric hood structure.According to an embodiment: the integral polymeric hood structure includes a central opening and first and second side openings, wherein the central opening and the first and second side openings extend through the integral polymeric hood structure in a longitudinal direction across the at least one deck.According to the present invention, a method of making a user support for vehicles includes: providing a frame having a lower portion and an upright rear portion; forming a homogeneous one-piece polymeric hood structure using an additive process including forming an outer layer of polymeric material extending around at least a portion of a porous mesh matrix such that the outer layer of polymeric material is integrally formed with the porous mesh matrix; and attaching an elastic pad to a front side of the one-piece polymeric hood structure.In one aspect of the invention, the method includes: utilizing an additive process to form the resilient pad from a material having greater elasticity than the polymeric material of the hood structure, wherein the at least one pad includes a resilient porous mesh matrix.In one aspect of the invention, the method includes: utilizing an additive process to form a sound pipe extending upwardly through the porous mesh matrix, the sound pipe being integrally formed with the porous mesh matrix and forming an opening at a front of the one-piece polymeric hood structure.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedUS 18 / 541,739

[0008] US 18 / 541,851

[0008] US 11 280 303

[0029]

Claims

A user support for vehicles, the user support comprising: a frame having a lower portion and a rear portion extending upwardly from the lower portion, the rear portion of the frame including an upper rear frame structure having an upper edge; a lower pad secured to the lower portion of the frame, the lower pad having an upwardly facing surface; a rear pad secured to the rear portion of the frame, the rear pad having a forwardly facing surface and an upper edge; an integral polymeric hood structure having a base secured to the upper rear frame structure and an upper hood structure extending upwardly above the upper edge of the upper rear frame structure; and an upper pad assembly attached to the one-piece polymeric hood structure whereby the upper pad assembly is positioned over the upper edge of the rear pad, the upper pad assembly including at least one pad having a forwardly facing elastic layer of material, a rear layer of material, and an elastic porous mesh matrix integrally formed with the forwardly facing elastic layer of material and with the rear layer of material to form an one-piece homogeneous polymeric structure, the porous mesh matrix being disposed between the forwardly facing elastic layer of material and the rear layer of material, the elastic porous mesh matrix having an integrally porous outer shell extending between the forwardly facing elastic layer of material and the rear layer of material whereby the porous outer shell is exposed and visible.The user support of claim 1, wherein: the integral polymeric hood structure is formed from nylon using an additive process, whereby the integral polymeric hood structure is homogeneous.The user support of claim 1, wherein: the at least one overlay comprises left and right overlays arranged in a side-by-side configuration, the left and right overlays formed from thermoplastic polyurethane using an additive process.The user support of claim 3, wherein: each of the left and right supports has a lower edge spaced from the upper edge of the rear bolster to form a horizontally extending gap.The user support of any of claims 1-4, wherein: the upper hood structure includes integral left and right outer structures each including elongate front and rear structures extending toward each other, thereby reducing a size of the gap between the elongate front and rear structures at upper ends of the elongate front and rear structures.The user support of claim 5, wherein: the integral polymeric hood structure includes a forwardly opening pocket formed by a pocket structure integrally formed with upper ends of the left and right outer structures; and including: a base having a pad disposed adjacent the forwardly opening pocket; and a support structure connecting the base to the rear portion of the frame.The user support of claim 5 or claim 6, wherein: the left and right outer structures extend upwardly and inwardly from the base.The user support of any of claims 5-7, wherein: the integral polymeric hood structure includes an integral porous mesh matrix extending across the gaps between the elongated front and rear structures, the integral porous mesh matrix having an exposed outer side between the elongated front and rear structures that is visible.The user support of any of claims 5-8, wherein: the elongated front and back structures comprise a porous mesh matrix and an impermeable outer layer extending around and encapsulating the porous mesh matrix.The user support of any of claims 1-9, wherein: the base of the one-piece polymeric hood structure includes a porous mesh matrix integrally formed with an impermeable outer layer extending around at least a portion of the porous mesh matrix, the porous mesh matrix of the base of the one-piece polymeric hood structure extending horizontally across a bottom portion of the base of the one-piece polymeric hood structure.The user support of any of claims 1-10, including: a sound passageway having a first end configured to be operatively coupled to a sound source whereby sound enters the first end of the sound passageway, wherein the sound passageway has a second end with at least one opening formed in the one-piece polymeric hood structure whereby sound entering the first end exits the at least one opening, and wherein at least a portion of the passageway comprises a tubular structure formed integrally with the porous lattice structure of the one-piece polymeric hood structure.The user support of any of claims 1-11, wherein: the at least one overlay includes a plurality of cavities formed in the backsheet of material; and the unitary polymeric hood structure includes a plurality of protrusions positioned in the cavities of the at least one overlay.A method of making a user support for vehicles, the method comprising: providing a frame having a bottom portion and an upright rear portion; forming a homogeneous one-piece polymeric hood structure using an additive process including forming an outer layer of polymeric material extending around at least a portion of a porous mesh matrix such that the outer layer of polymeric material is integrally formed with the porous mesh matrix; and attaching a resilient pad to a front side of the one-piece polymeric hood structure.The method of claim 13, comprising: utilizing an additive process to form the resilient overlay from a material having greater elasticity than the polymeric material of the hood structure, wherein the at least one overlay comprises a resilient porous mesh matrix.The method of claim 13 or claim 14, including: utilizing an additive process to form a sound pipe extending upwardly through the porous mesh matrix, wherein the sound pipe is integrally formed with the porous mesh matrix and forms an opening at a front of the one-piece polymeric hood structure.

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