# US 11,440,791 B2 · Seat cushion design manufacturing

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- Number: US 11,440,791 B2
- Document ID: US11440791B2
- Status: Granted
- Kind: B2
- Application number: 16/253,634
- Filed: 2019-01-22
- Published: 2020-07-23
- Granted: 2022-09-13
- Earliest claimed: 2019-01-22
- Assignees: Lear Corporation
- Applicants: Lear Corporation
- Inventors: Francesco Migneco; David Gallagher; Sajad Arabnejad; Mark Weaver
- Web page: https://patentgrep.com/patent/US11440791B2

## CPC

- B68G 7/00: Making upholstery (manufacturing upholstered panels B68G13/00 {; from plastics B29D99/0092}; sewing-machines D05B)
- A47C 7/029: {of non-adjustable shape adapted to a user contour or ergonomic seating positions}
- A47C 7/18: having foamed material included in cushioning part
- A47C 31/126: {for chairs}
- B29C 64/10: Processes of additive manufacturing
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- B60N 2/7017: {characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for}
- G01L 5/16: for measuring several components of force
- B68G: METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- A47C: CHAIRS; SOFAS; BEDS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B60N: SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- G01L: MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE (weighing G01G)

## Abstract

A method for manufacturing a seat cushion receives data of a specific occupant. A seat cushion is designed from the occupant data. The seat cushion is provided with a cellular structure from the occupant data. Another method for manufacturing a seat cushion receives boundary conditions for a seat cushion. Applicable mechanical properties are determined for the boundary conditions of the seat cushion. Applicable thermal properties are determined for the boundary conditions of the seat cushion. A seat cushion is designed with a varying cellular structure to satisfy the applicable mechanical properties and the applicable thermal properties.

## Claims

### Claim 1

A method for manufacturing a seat cushion, the method comprising:
receiving data of a specific occupant;
designing a seat cushion from the occupant data, with channels to be assembled directly to a seat frame;
manufacturing the seat cushion by three-dimensional printing the seat cushion with a cellular structure from the occupant data, with the channels; and
assembling the seat cushion directly to the seat frame by installing the seat frame into the seat cushion channels.

### Claim 2 (depends on 1)

The method of claim 1 further comprising a step of manufacturing the seat cushion as a seat bun or a seat back.

### Claim 3 (depends on 1)

The method of claim 1 further comprising a step of manufacturing the seat cushion as a head restraint.

### Claim 4 (depends on 1)

The method of claim 1 further comprising a step of receiving the occupant data as a pressure distribution.

### Claim 5 (depends on 1)

The method of claim 1 further comprising a step of receiving the occupant data as anthropometric data.

### Claim 6 (depends on 1)

The method of claim 1 further comprising assembling the seat cushion directly to a seat frame without an additional spring wire.

### Claim 7 (depends on 1)

The method of claim 1 further comprising assembling the seat cushion directly to a seat frame without an additional seat pan.

### Claim 8 (depends on 1)

The method of claim 1 further comprising manufacturing the seat cushion from metal wire.

### Claim 9 (depends on 1)

The method of claim 1 further comprising providing the seat cushion with visco-elastic properties to provide damping and impact absorption to omit an additional suspension.

### Claim 10

A method for manufacturing a seat cushion, the method comprising:
receiving data of a specific occupant;
designing a seat cushion from the occupant data;
manufacturing the seat cushion by three-dimensional printing the seat cushion from metal wire with a cellular structure from the occupant data; and
assembling the seat cushion directly to a seat frame.