Additively manufactured trim article

Patent metadata

Field	Value
Publication number	US-11279274-B1
Application number	US-202017123714-A
Country	US
Kind code	B1
Filing date	Dec 16, 2020
Priority date	Dec 16, 2020
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

A headrest assembly includes a lattice matrix having a plurality of three-dimensional (3D) cells. Each 3D cell of includes a node and a plurality of links outwardly extending from the node. The lattice matrix includes a plurality of sections including a first section having a first overall elastic modulus, a second section positioned adjacent to the first section and having a second overall elastic modulus that is higher than the first overall elastic modulus of the first section, and a third section positioned adjacent to the second section and having a third overall elastic modulus that is higher than the second overall elastic modulus of the second section. The lattice matrix is integrally constructed using an additive manufacturing technique, wherein the 3D cells of each section are provided in various patterns and cured to varying degrees to provide the varying overall elastic moduli of each section of the lattice matrix.

First claim

What is claimed is:

1. A headrest assembly, comprising:
a lattice matrix comprised of a plurality of interconnected links defining a plurality of sections, including a first section, a second section positioned behind the first section, and a third section positioned behind the second section, wherein the plurality of sections are positioned around a hollow core portion of the lattice matrix, and further wherein the first section includes a first elastic modulus that is lower than an elastic modulus of any one of the second section and the third section.

2. The headrest assembly of claim 1 , wherein the elastic modulus of the third section of the lattice matrix is higher than the elastic modulus of the second section of the lattice matrix.

3. The headrest assembly of claim 2 , wherein the second section is positioned between the third section of the lattice matrix and the first section of the lattice matrix.

4. The headrest assembly of claim 3 , wherein the hollow core portion is surrounded by the third section of the lattice matrix.

5. The headrest assembly of claim 4 , including:
a fourth section of the lattice matrix positioned on an opposite side of the hollow core portion relative to the third section of the lattice matrix.

6. The headrest assembly of claim 5 , wherein the elastic modulus of the third section of the lattice matrix is higher than an elastic modulus of the fourth section of the lattice matrix.

7. The headrest assembly of claim 1 , including:
a support armature having an upper portion thereof received in the hollow core portion of the lattice matrix.

8. The headrest assembly of claim 7 , wherein the support armature includes first and second support posts outwardly extending from the lattice matrix.

9. The headrest assembly of claim 8 , wherein the support armature is comprised of a metal material, and further wherein the lattice matrix is comprised of a polymeric material.

10. The headrest assembly of claim 1 , wherein the plurality of sections of the lattice matrix are integrated to define a unitary member.

11. A trim article, comprising:
a lattice matrix, wherein the lattice matrix includes:
an outer layer having a first overall elastic modulus;
an innermost layer having a second overall elastic modulus that is higher than the first overall elastic modulus of the outer layer, wherein the innermost layer surrounds a hollow core portion of the lattice matrix; and
one or more intermediate layers disposed between the outer layer and the innermost layer, wherein the one or more intermediate layers include a third overall elastic modulus that is higher than the first overall elastic modulus of the outer layer and less than the second overall elastic modulus of the innermost layer.

12. The trim article of claim 11 , wherein the one or more intermediate layers are comprised of a plurality of three-dimensional (3D) cells, and further wherein each 3D cell of the plurality of 3D cells includes a node and a plurality of links outwardly extending from the node.

13. The trim article of claim 12 , wherein the plurality of 3D cells includes first and second groups of 3D cells, wherein each 3D cell of the first group of 3D cells includes a first elastic modulus that is lower than a second elastic modulus of each 3D cell of the second group of 3D cells.

14. The trim article of claim 13 , wherein the innermost layer is comprised of a plurality of 3D cells, wherein each 3D cell of the plurality of 3D cells of the innermost layer includes a node and a plurality of links outwardly extending from the node.

15. The trim article of claim 14 , wherein the plurality of 3D cells of the innermost layer includes first and second groups of 3D cells, wherein each 3D cell of the first group of 3D cells of the innermost layer includes a first elastic modulus that is lower than a second elastic modulus of each 3D cell of the second group of 3D cells of the innermost layer.

16. The trim article of claim 15 , wherein more than 50% of the plurality of 3D cells of the innermost layer are 3D cells from the second group of 3D cells of the innermost layer.

17. A headrest assembly, comprising:
a lattice matrix comprised of a plurality of three-dimensional (3D) cells, wherein each 3D cell of the plurality of 3D cells includes a node having a plurality of links outwardly extending therefrom, and further wherein the lattice matrix includes a plurality of sections including a first section having a first overall elastic modulus, a second section positioned adjacent to the first section and having a second overall elastic modulus that is higher than the first overall elastic modulus of the first section, and a third section positioned adjacent to the second section and having a third overall elastic modulus that is higher than the second overall elastic modulus of the second section, wherein the third section surrounds a hollow core portion of the lattice matrix.

18. The headrest assembly of claim 17 , wherein the plurality of 3D cells includes a first group of 3D cells having a first elastic modulus and a second group of 3D cells having a second elastic modulus that is higher than the first elastic modulus of the first group of 3D cells.

19. The headrest assembly of claim 18 , wherein the second section of the lattice matrix includes 3D cells from the first and second groups of 3D cells.

20. The headrest assembly of claim 19 , wherein the third section of the lattice matrix includes 3D cells from the first and second groups of 3D cells, and further wherein the third section of the lattice matrix includes a higher concentration of 3D cells from the second group of 3D cells as compared to the second section of the lattice matrix.

Assignees

• Ford Global Tech Llc

Inventors

• Selvasekar Siddharthan
• Fredriksson Chris
• Maloney Patrick
• Tamhankar Sangram
• Vannieulande Kevin

Classifications

• B60N2002/899

  characterised by structural or mechanical details not otherwise provided for · CPC title

• B60N2/809

  vertically slidable · CPC title

• B60N2/7017

  characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for · CPC title

• B60N2/80 Primary

  Head-rests · CPC title

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title