Sheet components

Abstract

To provide a seat component that allows the seat cover and seat pad to be properly integrated even in the area where the seat cover heater is installed. [Solution] The seat cushion 1 comprises a cushion pad 10 made of a foamed molded body, a cushion cover 20 placed over the cushion pad 10, and a planar heater base material 32 disposed between the cushion cover 20 and the cushion pad 10. The cushion pad 10 is foam-molded so that its molding material flows into a gap 40 created between a bent portion 23 that bends to protrude to the seat surface side of the cushion cover 20 through a first through-hole 33 of the heater base material 32 and the heater base material 32, thereby filling the gap 40 so as to become integrated with the bent portion 23.

Description

[Technical Field]

[0001] The present invention relates to a component of a seat. More specifically, the present invention relates to a component of a seat provided with a heater for warming a seated occupant. [Background Art]

[0002] Patent Document 1 discloses a seat cushion obtained by foam-molding a seat pad integrally with a seat cover. The seat cushion has a planar heater disposed between the seat cover and the seat pad. The heater is pre-bonded to the back surface of the seat cover. Further, the heating wires of the heater are covered from the back side of the seat by a low-air-permeability face material. Therefore, during foam molding of the seat pad, the molding material is blocked by the low-air-permeability face material and is less likely to impregnate the heater side. As a result, the seat pad is prevented from being molded around the heating wires.

[0003] Patent Document 2 discloses a seat cushion having an uneven shape on the seat surface. The seat cushion has a seat cover pre-molded into a curved shape so as to form unevenness on the surface thereof. A seat pad is foam-molded so as to be integrated with this seat cover. Thereby, the seat pad is molded along the uneven shape. [Prior Art Documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Application Publication No. 2012-35671 [Patent Document 2] Japanese Unexamined Patent Application Publication No. 2024-162414 [Summary of the Invention] [Problem to be Solved by the Invention]

[0005] In the above-mentioned Reference 1, the molding material does not flow to the area where the seat cover heater is bonded. Therefore, if, for example, the heater from Reference 1 is installed on the back side of the seat cover from Reference 2, the molding material will not flow to the seat cover, and the seat pad will not be molded to conform to the uneven shape of the seat cover. As a result, there is a concern that the seat surface will not be able to have cushioning properties. Therefore, we provide a seat component that allows the seat cover and seat pad to be properly integrated even in the area where the seat cover heater is installed. [Means for solving the problem]

[0006] To solve the above problems, the constituent members of the sheet of the present invention take the following measures.

[0007] The first invention of the present invention is a sheet component comprising a sheet pad made of a foamed molded body, a sheet cover placed over the sheet pad, and a planar heater base material disposed between the sheet cover and the sheet pad, wherein the sheet pad is foam-molded so that its molding material flows into the gap created between the bent portion, which is bent so as to protrude to the sheet surface side of the sheet cover through a first through hole in the heater base material, and the filling portion that fills the gap so as to be integrated with the bent portion.

[0008] According to the above configuration, the filling portion of the seat pad is molded integrally with the bending portion. This allows the seat cover and seat pad to be properly integrated even in the area where the heater base material of the seat cover is provided. Furthermore, the bending portion can be properly cushioned.

[0009] The second aspect of the present invention is a component of the seat in which, in the first aspect described above, the heater base material has a second through hole at a position facing the seat surface portion so as to allow molding material to flow into the seat surface portion that is separated from the bent portion of the seat cover. With this configuration, the seat pad is integrated with the seat surface portion of the seat cover by passing through the second through hole of the heater base material. This allows the seat cover and the seat pad to be integrated more appropriately.

[0010] The third aspect of the present invention is a sheet component in which, in the second aspect described above, the heater base material has a mesh structure, and the first through-hole and the second through-hole are formed by the holes in the mesh structure. With the above configuration, the first through-hole and the second through-hole can be easily formed by the mesh structure. Furthermore, the area of ​​the heater base material that is impregnated by the holes in the mesh structure can be reduced. As a result, the heater base material is less likely to harden, and deterioration of the seat's ride comfort can be suppressed.

[0011] The fourth invention of the present invention is a sheet component that, in any of the first to third inventions described above, has a plurality of adhesive portions that partially adhere the heater substrate to the sheet cover, separate from the adhesion by the sheet pad. With this configuration, the adhesive portions can prevent the heater substrate from shifting relative to the sheet cover due to the molding pressure of the sheet pad. Furthermore, by dispersing the adhesive portions, the heater substrate can be properly adhered to the sheet cover over a wide area while minimizing obstruction of the flow of the molding material.

[0012] The fifth invention of the present invention is that, in any of the first to third inventions described above, the sheet cover is a sheet component made of a molded material formed into the shape having the bent portion. With the above configuration, the bent portion and the gap between the bent portion and the heater base material can be appropriately formed. [Brief explanation of the drawing]

[0013] [Figure 1] This is a plan view of a seat cushion according to the first embodiment. [Figure 2] This is a plan view of a seat cushion, focusing on the heater and adhesive parts. [Figure 3] This is a cross-sectional view taken along line III-III in Figure 1. [Figure 4] This is a cross-sectional view taken along line IV-IV in Figure 2. [Modes for carrying out the invention]

[0014] <First Embodiment> The embodiments for carrying out the present invention will be described below with reference to Figures 1 and 4. In the following description, when directions such as front, back, up, down, left, and right are indicated, they refer to the respective directions shown in each figure. Also, when "seat width direction" is indicated, it refers to the left-right direction of the seat cushion 1, which will be described later.

[0015] <Seat cushion> First, a seat cushion 1 according to the first embodiment of the present invention will be described. As shown in Figures 1 and 3, the seat cushion 1 forms the seating portion of an automobile seat. The seat cushion 1 has a cushion pad 10 that forms a cushioning material and a cushion cover 20 that covers the cushion pad 10. The cushion cover 20 has a plurality of bent portions 23 that are bent so as to protrude upward (towards the front of the seat) from various points on its surface. Each bent portion 23 forms an uneven shape on the surface of the cushion cover 20 (see Figure 3). Here, the seat cushion 1 corresponds to the "seat component" of the present invention.

[0016] Furthermore, the cushion pad 10 has a filling portion 13 that is foam-molded along each bent portion 23. Each filling portion 13 provides cushioning to each bent portion 23. As a result, each bent portion 23 deforms softly under the weight of the person sitting on it. In this way, the filling portion 13 can appropriately improve the seating comfort of the seat cushion 1.

[0017] As shown in Figures 2 and 4, the seat cushion 1 has a heater 30 provided on the back side of the cushion cover 20. The heater 30 can warm the buttocks of the person sitting. The heater 30 has a planar heater base material 32 that is assembled to the back side of the cushion cover 20 via an adhesive portion 50. The heater base material 32 has a mesh structure across its entire surface.

[0018] As shown in Figure 3, the cushion pad 10 is foam-molded integrally with the cushion cover 20 and the heater 30. That is, the cushion cover 20 and the heater 30 are set in a molding die (not shown) for foam-molding the cushion pad 10. A predetermined gap 40 is formed between each bent portion 23 of the cushion cover 20 and the heater base material 32. When the molding material for the cushion pad 10 is injected, it flows into the gap 40 through the first through-holes 33 formed by the mesh structure of the heater base material 32.

[0019] By the foam-molding of the cushion pad 10, the filling portion 13 of the cushion pad 10 is formed to fill the gap 40. Then the filling portion 13 is integrated with each bent portion 23. In this way, since the heater base material 32 has a mesh structure, the molding material can pass through the heater base material 32 and flow to the cushion cover 20. Thereby, the cushion pad 10 can be properly integrated even in the region of the cushion cover 20 where the heater base material 32 is provided. Moreover, by providing the filling portion 13 along each bent portion 23, the seating comfort of the seat cushion 1 can be appropriately improved.

[0020] <Cushion Pad> Hereinafter, each configuration of the above-described seat cushion 1 will be described in detail. As shown in Figure 1 and Figure 3, the cushion pad 10 includes a main top plate 11 that supports the seated person's buttocks from below, and a pair of left and right side top plates 12 that support the seated person's buttocks from the left and right sides. Each side top plate 12 forms a convex shape projecting upward relative to the main top plate 11. Here, the cushion pad 10 corresponds to the "seat pad" of the present invention.

[0021] <Cushion Cover> As shown in Fig. 1, the cushion cover 20 is a single member formed by vacuum-forming a vinyl chloride resin into a predetermined surface shape. The cushion cover 20 includes a main cover 21 that covers the top plate main portion 11 of the cushion pad 10, and respective side covers 22 that cover respective top plate side portions 12. Each side cover 22 is formed in a convex shape projecting upward beyond the main cover 21 so as to conform to the convex shape of the corresponding top plate side portion 12. Here, the cushion cover 20 corresponds to the "seat cover" of the present invention.

[0022] The main cover 21 of the cushion cover 20 has respective bent portions 23 that curve to protrude upward, and a groove portion 24 formed between the respective bent portions 23. Each bent portion 23 is formed to have a substantially rhombic shape when viewed in plan. This allows the main cover 21 to have a highly designable shape in which a plurality of rhombic patterns are arranged substantially regularly. Further, each groove portion 24 is formed to extend in a substantially lattice shape obliquely intersecting along the main cover 21. Here, the groove portion 24 corresponds to the "seat surface portion" of the present invention.

[0023] A predetermined surface treatment is applied to the surface of the cushion cover 20. This can improve the wear resistance of the cushion cover 20. Further, a primer treatment is applied to the back surface of the cushion cover 20. This can appropriately enhance the adhesiveness of the cushion cover 20 to the cushion pad 10.

[0024] <Heater> As shown in Fig. 2, the heater 30 includes the heater base material 32 and a heating wire 31 fixed to the heater base material 32. The heater base material 32 is, for example, a mesh-woven cloth member such as cheesecloth. The heater base material 32 has a plurality of through holes 33, 34 formed by its mesh structure. The heating wire 31 is integrally joined to the back surface of the heater base material 32 in a meandering shape along the heater base material 32. The heating wire 31 is joined to the heater base material 32, for example, by welding a resin (not shown) provided around the heating wire to the heater base material 32. Note that the heating wire 31 may be fixed to the heater base material 32 by, for example, sewing. Further, the heating wire 31 may be joined to the surface of the heater base material 32.

[0025] <Adhesive part> As shown in Figures 2 and 4, the seat cushion 1 has multiple adhesive parts 50 that adhere the surface of the heater base material 32 to the cushion cover 20 from below. Each adhesive part 50 is a strip of double-sided tape and is attached to the surface of the heater base material 32 so as to extend in a long length in the left-right direction. Each adhesive part 50 is provided at a predetermined distance from each other in the front-rear direction. By distributing the adhesive parts 50 in this way, obstruction of the flow of the molding material during foam molding of the cushion pad 10 can be suppressed. Note that each adhesive part may be attached so as to extend in a long length in the front-rear direction and provided at a distance from each other in the left-right direction.

[0026] <Adhesion of heater substrate> As shown in Figures 3 and 4, the heater base material 32 is bonded to the pre-formed cushion cover 20 from below via adhesive portions 50. This bonds the heater base material 32 to each groove portion 24 of the cushion cover 20. The bonding of the heater base material 32 creates a gap 40 between the heater base material 32 and each bent portion 23. Furthermore, the through holes 33 and 34 of the heater base material 32 are divided into a first through hole 33 positioned opposite each bent portion 23 and a second through hole 34 positioned opposite each groove portion 24.

[0027] <Foam molding of cushion pads> The cushion cover 20 and heater 30, which are bonded to each other, are set in a mold (not shown). Specifically, the cushion cover 20 is set in an overlapping manner on the molding surface that forms the surface shape of the pad surface of the mold. Then, the molding material is poured into the cavity of the mold, and the cushion pad 10 is foam-molded. Because the cushion cover 20 and heater 30 are bonded together in advance by the adhesive part 50, displacement of the heater 30 due to the molding pressure of the cushion pad 10 can be prevented.

[0028] As shown in Figure 3, the molding material flows into each gap 40 through the first through-hole 33 of the heater base material 32. This causes the filling portion 13 of the cushion pad 10 to be foamed and molded to integrate with each bent portion 23. The molding material also flows into each groove 24 through the second through-hole 34 of the heater base material 32. Therefore, the cushion pad 10 is foamed and molded to integrate with each groove 24. In this way, the cushion pad 10 is integrated with the main cover 21 through the through-holes 33 and 34 of the heater base material 32. In other words, the cushion pad 10 can be properly integrated with the cushion cover 20, including the area where the heater 30 is provided. This further enhances the integration of the cushion cover 20 with respect to the cushion pad 10.

[0029] Furthermore, by filling the gap 40 between each bent portion 23 and the heater base material 32 with the filling portion 13, each bent portion 23 can be appropriately cushioned. This improves the seating comfort of the seat cushion 1 and stabilizes the design shape of each bent portion 23 so that it does not sag.

[0030] By making the heater base material 32 a mesh structure, the area of ​​the heater base material 32 that is impregnated with the molding material can be reduced. As a result, the heater base material 32 is less likely to harden due to the foam molding of the cushion pad 10. This reduces the feeling of foreign matter in the seat cushion 1 and further improves the sitting comfort.

[0031] To summarize, the sheet components according to the first embodiment have the following configuration. In the following, the reference numerals in parentheses correspond to the respective components shown in the above embodiment.

[0032] In other words, the sheet component (1) includes a sheet pad (10) made of a foamed molded body, a sheet cover (20) placed over the sheet pad (10), and a planar heater base material (32) disposed between the sheet cover (20) and the sheet pad (10). The sheet pad (10) is foam-molded so that its molding material flows into a gap (40) created between a bent portion (23) that bends through a first through-hole (33) of the heater base material (32) to protrude to the sheet surface side of the sheet cover (20), and has a filling portion (13) that fills the gap (40) so as to become integrated with the bent portion (23).

[0033] According to the above configuration, the filling portion (13) of the seat pad (10) is molded integrally with the bending portion (23). As a result, the seat cover (20) and the seat pad (10) can be properly integrated even in the area where the heater base material (32) of the seat cover (20) is provided. In addition, the bending portion (23) can be properly given cushioning properties.

[0034] Furthermore, the heater base material (32) is a sheet component (1) having a second through hole (34) at a position facing the seat surface (24) so ​​as to allow molding material to flow into the seat surface (24) that has separated from the bent portion (23) of the seat cover (20). With the above configuration, the seat pad (10) is integrated with the seat surface (24) of the seat cover (20) by passing through the second through hole (34) of the heater base material (32). This allows the seat cover (20) and the seat pad (10) to be integrated more appropriately.

[0035] Furthermore, the heater base material (32) has a mesh structure, and the holes in the mesh structure form a first through-hole (33) and a second through-hole (34) in the sheet component (1). With the above configuration, the first through-hole (33) and the second through-hole (34) can be easily formed by the mesh structure. In addition, the holes in the mesh structure reduce the area in which the molding material of the heater base material (32) is impregnated. As a result, the heater base material (32) is less likely to harden, and deterioration of the seat's ride comfort can be suppressed.

[0036] Furthermore, the sheet component (1) has multiple adhesive parts (50) that partially adhere the heater base material (32) to the sheet cover (20), separate from the adhesion by the sheet pad (10). With the above configuration, the adhesive parts (50) can prevent the heater base material (32) from shifting relative to the sheet cover (20) due to the molding pressure of the sheet pad (10). Also, by dispersing the adhesive parts (50), the heater base material (32) can be properly adhered to the sheet cover (20) over a wide area while minimizing obstruction of the flow of the molding material.

[0037] Furthermore, the sheet cover (20) is a sheet component (1) made of a molded material that has been formed into a shape having a bent portion (23). With the above configuration, the bent portion (23) and the gap (40) between the bent portion (23) and the heater base material (32) can be appropriately formed.

[0038] <Other Embodiments> Although the present invention has been described above using one embodiment, the present invention can be implemented in various forms other than those described above.

[0039] 1. The seat components can be applied not only to the seat cushion but also to the seat back. Furthermore, the seat components can be widely applied not only to automobile seats but also to seats used in various vehicles other than automobiles, such as trains, aircraft, ships, and gaming chairs.

[0040] 2. The heater base material may be a mesh-like material made of resin or metal, in addition to a fabric material. The heater base material does not have to be entirely mesh-like; it may be partially mesh-like. Furthermore, even if the heater base material does not have a mesh structure, it is sufficient if it has a first through-hole at a position opposite to the bend of the seat cover. The heater base material does not have to be bonded to the seat cover during the foam molding of the seat pad.

[0041] 3. The seat cover may be molded using a different mold than the one used for the seat pad, or it may be molded using the same mold as the seat pad. In the latter case, the seat cover is molded first, and then the heater is bonded to the seat cover without demolding, and the seat pad is foam-molded.

[0042] 4. The adhesive parts may be made of double-sided tape or other adhesives. For example, a spray adhesive may be applied to the back of the seat cover, in which case it is not necessary to disperse the adhesive and it can be applied broadly and evenly to the seat cover. The adhesive parts may be arranged in a grid pattern or regularly spaced dots, or in any other arbitrary arrangement, as long as they are dispersed from one another. [Explanation of symbols]

[0043] 1. Seat cushion (component of the seat) 10 Cushion pads (seat pads) 11 Main top panel 12. Tabletop side 13 Filling section 20 Cushion Covers (Seat Covers) 21 Main Cover 22 Side cover 23 Bending section 24 Groove (seat surface) 30 Heater 31 Heating wire 32 Heater base material 33 First through hole 34 Second through hole 40 gaps 50 Adhesive part

Claims

1. A component of the sheet, A sheet pad made of a foamed molded body, A seat cover that is placed over the seat pad, It comprises a planar heater base material disposed between the seat cover and the seat pad, The sheet pad is a sheet component having a filling portion that fills the gap so as to become integrated with the bent portion, by foam molding so that the molding material flows into the gap created between the bent portion, which is bent so as to protrude to the sheet surface side of the sheet cover through the first through hole of the heater base material, and the heater base material.

2. A component of the sheet according to claim 1, The heater base material is a sheet component having a second through hole at a position opposite to the seat surface portion so as to allow molding material to flow into the seat surface portion that is separated from the bent portion of the seat cover.

3. A component of the sheet according to claim 2, A sheet component in which the heater substrate has a mesh structure, and the first through-hole and the second through-hole are formed by the holes in the mesh structure.

4. A component of a sheet according to any one of claims 1 to 3, A sheet component having multiple adhesive portions for partially adhering the heater base material to the sheet cover, separate from the adhesive provided by the sheet pad.

5. A component of a sheet according to any one of claims 1 to 3, The aforementioned seat cover is a component of a sheet made of a molded material that has been formed into the shape having the bent portion.

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