Additively manufactured trim article

Patent metadata

Field	Value
Publication number	US-12434429-B2
Application number	US-202318180927-A
Country	US
Kind code	B2
Filing date	Mar 9, 2023
Priority date	Dec 16, 2020
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

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 method for manufacturing a headrest bun, comprising the steps of:
additively manufacturing a first section of a lattice matrix comprising a plurality of three-dimensional (3D) cells, wherein each cell of the plurality of 3D cells of the first section of the lattice matrix includes a node and a plurality of links extending outwardly from the node, and further wherein the step of additively manufacturing the first section of the lattice matrix further comprises providing a build material in a layer-by-layer deposition process and heating the build material to provide the first section of the lattice matrix with a first elastic modulus, wherein the step of heating the build material to provide the first section of the lattice matrix includes heating a thermocurable material in a layer-by-layer manner for a first time interval;
additively manufacturing a second section of the lattice matrix comprising a plurality of three-dimensional (3D) cells, wherein each cell of the plurality of 3D cells of the second section of the lattice matrix includes a node and a plurality of links extending outwardly from the node, and further wherein the step of additively manufacturing the second section of the lattice matrix further comprises depositing the build material in the layer-by-layer deposition process and heating the build material to provide the second section of the lattice matrix with a second elastic modulus that is higher than the first elastic modulus of the first section of the lattice matrix, wherein the step of heating the build material to provide the second section of the lattice matrix with a second elastic modulus further includes, heating portions of the second section of the lattice matrix on a voxel level to form 3D cells having the second elastic modulus;
forming a hollow core portion within the lattice matrix; and
providing a support armature within the hollow core portion to couple the lattice matrix to the support armature to form a headrest assembly.

2. The method of claim 1 , wherein the step of heating the build material to provide the second section of the lattice matrix includes heating the build material in a layer-by-layer manner for a second time interval that is greater than the first time interval.

3. A method of forming a trim article, comprising the steps of:
depositing a thermocurable composition in a layer-by-layer deposition process using an additive manufacturing process to form a first section of a lattice matrix;
heating the first section of the lattice matrix with an energy source for a first time interval to cure the first section of the lattice matrix, such that the first section of the lattice matrix includes a first elastic modulus;
printing the thermocurable composition in a layer-by-layer deposition process using the additive manufacturing process to form a second section of the lattice matrix that is positioned on the first section of the lattice matrix;
heating portions of the second section of the lattice matrix with the energy source for a second time interval that is greater than the first time interval, such that the second section of the lattice matrix includes a second elastic modulus that is higher than the first elastic modulus of the first section of the lattice matrix, further wherein the step of heating portions of the second section of the lattice matrix with an energy source for a second time interval further includes, heating portions of the second section of the lattice matrix on a voxel level to form 3D cells having the second elastic modulus;
printing the thermocurable composition in a layer-by-layer deposition process using the additive manufacturing process to form a third section of the lattice matrix that is positioned on the second section of the lattice matrix;
heating portions of the third section of the lattice matrix with the energy source for a third time interval that is greater than the second time interval, such that the third section of the lattice matrix includes a third elastic modulus that is higher than the second elastic modulus of the second section of the lattice matrix;
forming a hollow core portion within the lattice matrix, such that the third section of the lattice matrix surrounds the hollow core portion and forms a lower opening to the hollow core portion; and
providing a support armature within the hollow core portion via the lower opening to couple the lattice matrix to the support armature to form a headrest assembly.

4. The method of claim 3 , wherein the step of heating portions of the third section of the lattice matrix with the energy source for a third time interval further includes, heating portions of the third section of the lattice matrix on a voxel level to form 3D cells having the third elastic modulus.

5. The method of claim 4 , wherein the 3D cells of the second and third sections of the lattice matrix each include a node and a plurality of links outwardly extending from the node.

6. The method of claim 5 , wherein the second time interval is at least two times greater than the first time interval, and further wherein the third time interval is at least two times greater than the second time interval.

Assignees

• Ford Global Tech Llc

Inventors

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

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B29L2031/30

  Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)} · CPC title

• Y02P10/25

  Process efficiency · CPC title

• B60N2/70

  Upholstery springs {; Upholstery} · CPC title