Vehicle seat

Abstract

The purpose of the present invention is to provide a vehicle seat in which the inner side of a trim cover can be filled with a stock solution of an unfoamed foamable resin in advance, whereby it is possible to prevent the thickness of an outer pad from being insufficient or the density of the outer pad from being uneven, and to improve the efficiency of a process for manufacturing a headrest. A vehicle seat (S1) is provided with a headrest (3) that supports the head of a seated person. The headrest (3) is provided with: a headrest strut (30) forming a skeleton; and a headrest pad (40) covering the headrest pillar (30), the headrest pad (40) having: an inner headrest pad (41) attached to the headrest pillar (30); and an outer headrest pad (46) that covers the inner headrest pad (41) and contains a foamable resin, and the inner headrest pad (41) has a guide groove (43) that guides a stock solution of the unfoamed foamable resin.

Description

Technical Field

[0001] The invention relates to a vehicle seat, in particular to a vehicle seat with a built-in cushion. Background Art

[0002] The vehicle seat includes a plurality of supporting members for supporting the seated person. Specifically, the vehicle seat includes a seat cushion, a seat back, a headrest, and an armrest, each of which is configured to support the seated person's buttocks, back, head, and arms. This can reduce fatigue of the seated person who sits for a long time.

[0003] In addition, Patent Document 1 discloses a headrest which, in addition to its original function of supporting the head of a seated person, also has the ability to absorb the impact when a seated person in a rear seat is hit from behind. Specifically, the headrest disclosed in Patent Document 1 includes: a headrest support, a cushion, and a decorative cover, and the cushion has: an inner cushion containing a hard foaming resin, and an outer cushion containing a soft foaming resin. Therefore, the inner cushion can absorb the impact when a seated person in a rear seat is hit from behind, and the outer cushion can support the head of the seated person without generating a reaction force.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Laid-Open No. 9-85755 Summary of the invention

[0007] Problems to be solved by the invention

[0008] The headrest disclosed in Patent Document 1 efficiently absorbs and eliminates the impact of a rear seat occupant in a collision from behind, thereby protecting the occupant and improving safety. However, from the perspective of improving the quality of the headrest and improving the efficiency of the manufacturing process, further improvements are required. The manufacturing process of the headrest is described in detail below.

[0009] Regarding the headrest disclosed in Patent Document 1, first, an inner pad made of foamed polypropylene is mounted on a headrest pillar. Next, the headrest pillar and the inner pad are housed inside a decorative cover in a manner covered by the decorative cover. Then, a stock solution of unfoamed polyurethane resin is injected, and the inside of the decorative cover is filled with the stock solution of polyurethane resin. Finally, the polyurethane resin is foamed to form an outer pad, thereby completing the headrest.

[0010] Here, when the stock solution of the unfoamed polyurethane resin is injected, the flow of the stock solution is blocked by the headrest pillar and the inner pad contained inside the decorative cover, and it may take a long time to fill the inner side of the decorative cover. Therefore, before the stock solution of the foamed polyurethane resin fills the inner side of the decorative cover, the foaming molding of the polyurethane resin starts, which may cause the thickness of the outer pad to be insufficient or the density to be uneven.

[0011] The present invention is made in view of the above-mentioned problems, and its purpose is to provide a vehicle seat, which can fill the inner side of the decorative cover with unfoamed foamable resin stock solution in advance, thereby preventing the outer pad from having insufficient thickness or uneven density and achieving efficiency in the manufacturing process of the headrest.

[0012] Technical means of solving problems

[0013] The problem is solved by the following manner: According to the vehicle seat of the present invention, it is a vehicle seat including a support member for supporting a seated person, wherein the support member comprises: a frame forming the skeleton of the support member; and a pad covering the frame, the pad comprising: a first pad installed on the frame; and a second pad covering the first pad and containing a foamable resin, the first pad having a guide portion, the guide portion guiding the liquid of the unfoamed foamable resin.

[0014] According to the structure, the liquid of the unfoamed foaming resin is guided by the guide portion formed on the first pad, so that the inner side of the decorative cover can be filled in advance. This prevents the outer pad from having insufficient thickness or uneven density due to starting the foaming of the liquid before filling, and improves the efficiency of the manufacturing process of the supporting member.

[0015] Furthermore, the guide portion may be a guide groove extending in a direction away from a position where the liquid of the foamable resin is injected.

[0016] According to the above configuration, the liquid of the unfoamed foamable resin can be guided by a simple configuration in which the guide groove is formed in the first pad, so that an increase in the cost of the vehicle seat can be suppressed.

[0017] Furthermore, the guide groove may be deepest at a center of the guide groove in the seat width direction and may become shallower as it moves away from the center of the guide groove in the seat width direction.

[0018] According to the above structure, the liquid of the unfoamed foamable resin is accurately guided along the guide groove, so that the inner side of the decorative cover can be filled in advance, thereby preventing the outer pad from having insufficient thickness or uneven density due to starting the foaming molding of the liquid before filling, and achieving efficiency in the manufacturing process of the headrest.

[0019] In addition, the guide groove may have a triangular pyramid shape.

[0020] According to the above configuration, the guide groove having a triangular pyramid shape can be easily formed by cutting the first spacer, thereby preventing the manufacturing process of the support member from becoming complicated.

[0021] In addition, it can be that: the first pad has: a first surface, facing the ejection nozzle that ejects the liquid; and a second surface, intersecting the first surface and allowing the liquid to flow downward, the guide groove is formed across the first surface and the second surface, and has: a first guide groove portion, formed on the first surface; and a second guide groove portion, formed on the second surface.

[0022] According to the above structure, the guide groove includes: a first guide groove portion for guiding the liquid on the first surface; and a second guide groove portion for guiding the liquid on the second surface. Therefore, the guide groove spans the first surface and the second surface to appropriately guide the liquid, so that the inner side of the decorative cover can be filled in advance, thereby preventing the outer pad from being insufficiently thick or unevenly dense due to the start of foaming of the liquid before filling, and achieving efficiency in the manufacturing process of the headrest.

[0023] Furthermore, the first gasket may include a connecting edge that connects the first surface and the second surface to each other, and the first guide groove portion and the second guide groove portion may be connected to each other at the connecting edge.

[0024] According to the structure, since the first guide groove portion and the second guide groove portion are connected to each other at the connecting edge, the liquid is appropriately guided by the guide groove spanning the first surface and the second surface, and the inner side of the decorative cover can be quickly and accurately filled, thereby preventing the outer pad from having insufficient thickness or uneven density due to starting the foaming of the liquid before filling, and realizing the efficiency of the manufacturing process of the headrest.

[0025] Furthermore, the first gasket may be formed with a fitting recess to be fitted with the frame, and the guide portion may be formed at a position different from the fitting recess.

[0026] According to the above configuration, by forming the guide portion, it is possible to suppress the first gasket from being insufficiently fitted to the frame.

[0027] In addition, the support member may be a headrest for supporting the seated person's head, and the first cushion may include: a support surface for supporting the seated person; and a mounting portion protruding in a direction orthogonal to the support surface and having an engaging portion for engaging with the frame.

[0028] According to the above configuration, the first pad can be easily mounted on the frame by engaging the engaging portion formed on the mounting portion with the frame, so that the manufacturing process of the headrest can be made more efficient.

[0029] In addition, the frame may include: a pair of parallel frames located at both ends in the seat width direction or both ends in the up-down direction, extending parallel to each other; and a connecting frame connecting the pair of parallel frames at the ends in the length direction of the pair of parallel frames, and the engaging portion is formed at a position overlapping with the connecting frame in a direction orthogonal to the support surface.

[0030] According to the above configuration, since the engaging portion is formed at a position overlapping with the connecting frame in the front-rear direction, it is possible to suppress the engaging state between the first gasket and the frame from being released unintentionally.

[0031] Furthermore, the engaging portion may be formed at a position overlapping the parallel frame in a direction perpendicular to the supporting surface.

[0032] According to the above configuration, since the engaging portion is formed at a position overlapping the parallel frame in the front-rear direction, it is possible to suppress the engaging state between the first gasket and the frame from being released unintentionally.

[0033] Effects of the Invention

[0034] According to the vehicle seat of the present invention, the inner side of the trim cover can be filled in advance with the stock solution of the unfoamed foamable resin, thereby preventing the outer pad from having insufficient thickness or uneven density and achieving efficiency in the manufacturing process of the headrest.

[0035] In addition, it is possible to suppress an increase in the cost of the vehicle seat.

[0036] In addition, it is possible to suppress complication of the manufacturing process of the support member.

[0037] In addition, it is possible to prevent the first gasket from being insufficiently fitted to the frame.

[0038] In addition, the manufacturing process of the headrest can be made more efficient.

[0039] In addition, it is possible to suppress the engagement state between the first gasket and the frame from being released unintentionally. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] [ Figure 1] is a three-dimensional view of a vehicle seat with the armrest in the storage position, viewed from the oblique front.

[0041] [ Figure 2 ] is a stereoscopic view of a vehicle seat with the armrest in the unfolded position, viewed from the oblique front.

[0042] [ Figure 3 ] is a three-dimensional view of the seat frame viewed from the oblique front.

[0043] [ Figure 4 ] is a front view of the backrest frame.

[0044] [ Figure 5 ] is a perspective view of the headrest viewed from obliquely below.

[0045] [ Figure 6 ] is a side cross-sectional view of the headrest.

[0046] [ Figure 7 ] is an exploded stereoscopic view of the headrest pillar and the first cushion viewed from the rear obliquely.

[0047] [ Figure 8 ] is a stereoscopic view of the headrest pillar with the first cushion installed, viewed from the oblique rear.

[0048] [ Fig. 9 ]yes Figure 8 AA cross-section diagram.

[0049] [ Fig.10 ] is a diagram showing a headrest in a state where a headrest pillar and a first pad are housed in a manner covered with a decorative cover and a spray nozzle is inserted into the decorative cover.

[0050] [ Fig.11 ] is a diagram showing a state in which a stock solution of polyurethane resin is injected.

[0051] [ Fig.12 ] is an exploded stereoscopic view of the headrest pillar and the first cushion of the modified example as viewed from the oblique rear.

[0052] [ Fig.13 ] is a stereoscopic view of the headrest pillar with the first cushion installed, viewed from the oblique rear.

[0053] [ Fig.14 ]yes Fig.13 BB cross-section diagram. DETAILED DESCRIPTION

[0054] Hereinafter, a vehicle seat according to an embodiment of the present invention will be described with reference to the accompanying drawings. However, the embodiment described below is intended to facilitate the understanding of the present invention and does not limit the present invention. That is, the present invention can of course be changed and improved without departing from its main purpose, and the present invention includes its equivalents.

[0055] In the following description, the materials, shapes, and sizes of seat components are merely specific examples and do not limit the present invention.

[0056] In addition, as an example of a vehicle seat, a vehicle seat mounted on a vehicle is listed below, and its structural example is described. However, the present invention is not limited to a vehicle seat mounted on a ground-moving vehicle with wheels such as a car or a train, and can also be applied to a seat mounted on an airplane or a ship that moves on other than the ground.

[0057] In the following description, the so-called "front-rear direction" refers to the front-rear direction of the vehicle seat, and is a direction consistent with the front-rear direction observed from the seated person sitting on the vehicle seat. In addition, the so-called "seat width direction" refers to the lateral width direction of the vehicle seat, and is a direction consistent with the left-right direction observed from the seated person sitting on the vehicle seat. In addition, the so-called "up-down direction" refers to the up-down direction of the vehicle seat, and is a direction consistent with the vertical direction when the vehicle is traveling on a horizontal plane. In addition, when simply referred to as "outside", it refers to the side closer to the outside in the direction from the center of the vehicle seat toward the outside, and when referred to as "inside", it refers to the side closer to the center in the direction from the outside toward the center of the vehicle seat.

[0058] <Overview of vehicle seat S1>

[0059] Figure 1 The perspective view of the vehicle seat S1 when the armrest 5 is located at the storage position is shown. Figure 2 The perspective view of the vehicle seat S1 when the armrest 5 is located in the deployed position is shown. Figure 3 It is a perspective view of the seat frame F1.

[0060] The vehicle seat S1 is, for example, a rear seat corresponding to a rear seat of a car, and includes a main seat and a passenger seat which are arranged side by side in a seat width direction.

[0061] The vehicle seat S1 is a seat that can be switched between a normal state in which a seated person can sit and a stowed state in which a seat body is stowed in a vehicle body floor.

[0062] Specifically, when the seat occupant operates the backrest operating lever 52 in the normal state, the vehicle seat S1 switches to the storage state in which the seat body is tilted forward and folded and stored in the vehicle body floor. In addition, the seat body is manually raised upward to return to the normal state from the storage state.

[0063] The vehicle seat S1 mainly includes: a main seat including a seat cushion 1 , a seat back 2 , and a headrest 3 ; an auxiliary seat including an armrest 5 and an auxiliary headrest 4 ; and a switching device 50 .

[0064] The seat cushion 1 is a support member for supporting the buttocks of a seated person, and is a seat portion for supporting the seated person from below. The seat cushion 1 has a cushion frame 10 (see Figure 3 ), a cushion 1a covering a cushion frame 10, and a decorative cover 1b covering the cushion frame 10 and the cushion 1a as main structures.

[0065] The seat back 2 is a support member for supporting the back of a seated person, and is a seat back that supports the back of a seated person from behind. The seat back 2 has a back frame 20 forming a framework of the seat back 2, a cushion 2a covering the back frame 20, and a decorative cover 2b covering the back frame 20 and the cushion 2a as main structures.

[0066] The headrest 3 is a support member for supporting the head of the seated person, and supports the head of the seated person from behind. The headrest 3 has a headrest support 30 forming the frame of the headrest 3, a headrest pad 40 covering the headrest support 30, and a decorative cover 3a covering the headrest support 30 and the headrest pad 40 as main structures. As described later, the headrest pad 40 includes an inner headrest pad 41 made of foamed polypropylene and an outer headrest pad 46 made of foamed polyurethane (see Figure 5 ).

[0067] The armrest 5 can be in a storage position stored in the seat back 2 and in an extended position extended from the storage position toward the front of the seat (see Figure 2 ). The armrest 5 has built-in electrical components 6 such as lighting equipment and audio equipment, and is larger than a normal armrest. The armrest 5 constitutes a part of the seat back 2 in the stowed position and functions as a seat back. On the other hand, it functions as an armrest in the deployed position. The armrest 5 is also generally called a "center armrest".

[0068] The armrest 5 is a supporting member for supporting the back or arms of the seated person. The armrest 5 has as main structures an armrest frame 5c forming the framework of the armrest 5, an armrest pad 5a covering the armrest frame 5c, and a decorative cover 5b covering the armrest frame 5c and the armrest pad 5a.

[0069] The sub-headrest 4 is a supporting member for supporting the head or arms of the seated person. The sub-headrest 4 includes a sub-headrest pillar 4b forming a framework of the sub-headrest 4, a pad (not shown) covering the sub-headrest pillar 4b, and a decorative cover 4a.

[0070] A switching device 50 for switching the vehicle seat S1 between the normal state and the stowed state is mounted on the left side of the seat back 2 in the seat width direction.

[0071] The switching device 50 mainly includes a locking member 51, a backrest operating lever 52, and a connecting cable 53 (see Figure 3 The locking member 51 is detachably engaged with a striker 54 provided on the vehicle body and is used to lock the rotation of the backrest frame 20. In addition, the backrest operating lever 52 is an operating member operated to release the locked state of the backrest frame 20. The connecting cable 53 connects the locking member 51 and the backrest operating lever 52.

[0072] In the above description, the switching device 50 can release the locked state of the locking member 51 by operating the backrest operating lever 52 when the seat body is in the normal state.

[0073] When the locked state is released, the seat back 2 is switched to a stowed state in which the seat back 2 is tilted forward by the force applied by the reclining device and is folded together with the seat cushion 1 and stowed in the vehicle body floor.

[0074] <Seat frame F1>

[0075] Next, the seat frame F1 will be described.

[0076] Figure 3 is a three-dimensional diagram of the seat frame F1. Figure 3 As shown, the seat frame F1 has a cushion frame 10, a backrest frame 20, a headrest pillar 30, and an armrest frame 5c as main structures.

[0077] <<Seat frame 10>>

[0078] The seat cushion frame 10 includes a substantially rectangular frame body, which mainly includes a side frame 11, a front frame 12, a rear frame 13, a disc frame 14, and a pressure-bearing member 15. The side frames 11 are arranged on the left and right sides of the seat cushion frame 10. The front frame 12 and the rear frame 13 connect the front end portion and the rear portion of each side frame 11, respectively. In addition, the plate-shaped disc frame 14 is installed between the front portions of each side frame 11. The pressure-bearing member 15 is installed on the disc frame 14 and the rear frame 13 and extends in a winding manner.

[0079] The rear end portion of the side frame 11 is connected to the back frame 20 via a seat cushion connection bracket 28 .

[0080] A seat cushion rotating device 16 that rotatably connects the seat cushion frame 10 to the back frame 20 is mounted on the rear end portion of the side frame 11 .

[0081] Furthermore, a support leg 17 is attached to the front end portion of the front frame 12 , which connects the seat cushion frame 10 to the vehicle body floor and supports the seat cushion frame 10 from below.

[0082] <<Backrest frame 20>>

[0083] like Figure 3 and Figure 4 As shown in FIG. 1 , the backrest frame 20 mainly includes a main frame 21 including a substantially rectangular frame-shaped body, a sub-frame 22, a plate-shaped panel frame 23, and a connecting frame 24. The main frame 21 and the T-shaped sub-frame 22 are arranged to be aligned with each other in the seat width direction. The connecting frame 24 connects the left and right side frames 21a and 21b constituting the side portions of the main frame 21 in the seat width direction.

[0084] The main frame 21 and the sub-frame 22 are mounted on the front surface of the panel frame 23 by welding.

[0085] The main frame 21 mainly includes left and right side frames 21a, side frames 21b, an upper frame 21c connecting the upper ends of the left and right side frames 21a and side frames 21b, and a lower frame 21d connecting the lower ends of the left and right side frames 21a and side frames 21b. The left and right side frames 21a, side frames 21b, upper frame 21c, and lower frame 21d are pipes and are fixed to each other by welding.

[0086] The lower frame 21 d is a member that is elongated in the seat width direction compared to the upper frame 21 c , and extends to the sub-frame 22 .

[0087] A plurality of substantially flat surfaces are formed on the front surface of the upper frame 21c at predetermined intervals in the seat width direction. A pair of headrest guides 21c1 for supporting the headrest pillars 30 are attached to the portions where these substantially flat surfaces are formed.

[0088] A reinforcement bracket 25A, a reinforcement bracket 25B, and a damper member 26 are provided in the frame of the main frame 21. The reinforcement bracket 25A has the function of connecting the panel frame 23 and the connecting frame 24 and reinforcing the back frame 20. The reinforcement bracket 25B has the function of connecting the side frame 21a and the connecting frame 24 and reinforcing the back frame 20. The damper member 26 has the function of absorbing the impact on the seat back 2.

[0089] An arm connection bracket 27 for connection with the handrail frame 5c is attached to the lower end of the inner side frame 21a. The arm connection bracket 27 rotatably supports the base end frame 5d of the handrail frame 5c.

[0090] A cushion connection bracket 28 for connection with the cushion frame 10 is attached to the lower end of the outer side frame 21b. The cushion connection bracket 28 is a plate-shaped member having a step, and is attached to the main frame 21 at the upper end and to the cushion frame 10 at the lower end.

[0091] A plurality of base connection brackets 29 are attached to the lower end portion of the lower frame 21d. The base connection brackets 29 play a role in connecting the main frame 21 to a base member that fixes the vehicle seat S1 to the floor of the vehicle body.

[0092] The subframe 22 mainly includes: a horizontal subframe 22a extending in the seat width direction; and a vertical subframe 22b connected at one end of the horizontal subframe 22a in the extending direction and extending in a long strip in the height direction of the backrest frame 20. The horizontal subframe 22a and the vertical subframe 22b are square pipes.

[0093] The horizontal sub-frame 22a is disposed at a substantially central portion in the height direction of the back frame 20. The horizontal sub-frame 22a is disposed so as to connect the side frames 21a of the main frame 21 and the vertical sub-frame 22b.

[0094] The vertical sub-frame 22b is disposed at the end opposite to the main frame 21 side among both ends in the seat width direction of the back frame 20. The lower end of the vertical sub-frame 22b is connected to the extended end of the lower frame 21d by welding.

[0095] like Figure 4 As shown in FIG. 1 , a portion of the panel frame 23 on one side of which the main frame 21 is mounted is formed with a plurality of reinforcing protrusions 23a that protrude toward the main frame 21. To be described in detail, the reinforcing protrusions 23a are formed in a portion of the panel frame 23 on which the main frame 21, the connecting frame 24, and the reinforcing bracket 25A are mounted. Therefore, the mounting rigidity of the main frame 21, the connecting frame 24, and the reinforcing bracket 25A relative to the panel frame 23 can be improved.

[0096] In addition, a plurality of reinforcing protrusions 23b protruding toward the sub-frame 22 are formed in a portion of the panel frame 23 on one side where the sub-frame 22 is mounted. The plurality of reinforcing protrusions 23b are arranged to sandwich the horizontal sub-frame 22a in the height direction of the backrest frame 20. Therefore, the rigidity of the sub-frame 22 can be further improved.

[0097] In addition, a reinforcing bar 23c extending in the height direction of the backrest frame 20 is formed in a portion of the panel frame 23 on the side where the subframe 22 is mounted. The reinforcing bar 23c extends in the up-down direction along the outer peripheral portion of the panel frame 23 located on the inner side in the seat width direction. The vertical subframe 22b is arranged to be sandwiched between the reinforcing bar 23c and the horizontal subframe 22a in the seat width direction. Therefore, the rigidity of the subframe 22 can be further improved.

[0098] <<Headrest pillar 30>>

[0099] like Figure 3 and Figure 4 As shown, the headrest support 30 includes a substantially inverted U-shaped frame, and has left and right side frames 31, an upper frame 32, and a support plate 33 as main structures. The side frames 31 and the upper frame 32 are made of pipes. On the other hand, the support plate 33 is a plate member.

[0100] The side frames 31 are located at both ends of the headrest pillar 30 in the left-right direction and extend in parallel with each other. The upper frame 32 connects the upper ends (ends in the length direction) of the left and right side frames 31. In addition, the inner headrest pad 41 (see FIG. 1 ) described later is mounted on the left and right side frames 31 and the upper frame 32. Figure 7 and Figure 8 ) is supported by a support plate 33. The left and right side frames 31 are equivalent to a pair of parallel frames, and the upper frame 32 is equivalent to a connecting frame.

[0101] like Figure 3 and Figure 7 As shown, the support plate 33 has a flat portion 33a at its center and a curved portion 33b curved forward at its periphery. In other words, the support plate 33 forms a receiving recessed portion for receiving and supporting an inner headrest pad 41 described later by the flat portion 33a and the curved portion 33b.

[0102] <Headrest pad 40>

[0103] Next, the headrest pad 40 will be described. Figure 5 This is a perspective view of the headrest 3 as viewed from obliquely below. As described above, the headrest 3 includes the headrest pillar 30, the headrest pad 40, and the decorative cover 3a as main components.

[0104] An inner headrest pad 41 for absorbing the impact of a rear seat occupant being hit from behind is attached to the headrest pillar 30. The inner headrest pad 41 is a molded body made of foamed polypropylene, which is a hard foaming resin.

[0105] The headrest pillar 30 and the inner headrest pad 41 are covered with an outer headrest pad 46 which is highly flexible and comfortably supports the head of the seated person. The outer headrest pad 46 is a molded body made of foamed polyurethane which is a soft foaming resin.

[0106] In this way, the headrest pad 40 is composed of a combination of molded bodies of foamed resin materials having different characteristics (hardness, that is, deformation characteristics with respect to load). Therefore, the impact absorption of the inner headrest pad 41 and the softness of the outer headrest pad 46 can achieve a balance between safety and comfort for the seated person. The inner headrest pad 41 is equivalent to the first pad, and the outer headrest pad 46 is equivalent to the second pad.

[0107] like Figure 5 and Figure 6 As shown, the inner headrest pad 41 includes a main body portion 42 having a substantially rectangular parallelepiped shape and a mounting portion 44 protruding from the main body portion 42 toward the rear of the seat. The main body portion 42 and the mounting portion 44 are integrally formed.

[0108] When the inner headrest pad 41 is installed on the headrest pillar 30, the main body 42 is located in front of the headrest pillar 30 to bear the load of the seated person's head. The main body 42 has an upper surface 42a, a lower surface 42b, a front surface 42c, a rear surface 42d, and a side surface 42e. The main body 42 is not limited to Figure 5 and Figure 6 Shape shown.

[0109] A guide groove 43 is formed in the main body 42, and the guide groove 43 guides the liquid body (stock solution) of the unfoamed foamed polyurethane. The details will be described later. In the forming of the outer headrest pad 46, first, the headrest 3 is turned over in a manner that the up-down direction becomes opposite, and the stock solution of the foamed polyurethane is injected from the nozzle insertion hole 3a1. Then, the stock solution of the foamed polyurethane foams, thereby the outer headrest pad 46 expands and is formed into a shape equivalent to the internal shape of the decorative cover 3a. Here, the timing when the stock solution of the foamed polyurethane starts to foam is preferably the timing after the stock solution completely fills the space inside the decorative cover 3a. In this way, it is possible to prevent the outer headrest pad 46 from being insufficiently thick or unevenly dense on the inner side of the decorative cover 3a. The inner headrest pad 41 of the present embodiment is provided with a guide groove 43 for guiding the raw liquid of the unfoamed foamed polyurethane so that the raw liquid of the foamed polyurethane quickly fills the space inside the trim cover 3 a .

[0110] The guide groove 43 is formed to extend in a direction away from the injection position of the raw liquid of the foamed polyurethane. More specifically, the guide groove 43 includes a lower surface guide groove 43a and a front surface guide groove 43b respectively formed on the lower surface 42b and the front surface 42c of the main body 42 of the inner headrest pad 41, and guides the raw liquid of the foamed polyurethane from the lower surface 42b of the main body 42 to the front surface 42c. Thus, after the raw liquid of the foamed polyurethane is injected from the lower side of the inner headrest pad 41, it is guided by the lower surface guide groove 43a to flow in the front-back direction, and then guided by the front surface guide groove 43b to flow in the up-down direction. The lower surface 42b and the front surface 42c correspond to the first surface and the second surface, respectively, and the lower surface guide groove 43a and the front surface guide groove 43b correspond to the first guide groove portion and the second guide groove portion, respectively.

[0111] The lower surface guide groove 43a has a central portion 43a1 located at the center in the seat width direction and having the deepest groove, and left and right side wall portions 43a2, the groove becoming shallower as it moves away from the central portion 43a1 in the seat width direction. The front surface guide groove 43b also has a central portion 43b1 and left and right side wall portions 43b2. In other words, the lower surface guide groove 43a and the front surface guide groove 43b have a triangular pyramid shape. Thus, the raw liquid of the unfoamed foamed polyurethane can be accurately guided to flow down along the guide groove 43, and the guide groove 43 can be easily formed by cutting the first gasket, thereby suppressing the complication of the manufacturing process.

[0112] like Figure 6 As shown, the mounting portion 44 has: a supported surface 44a that contacts the support plate 33; and a mounting side surface 44b, which is formed with an engaging portion 45 that engages with the side frame 31 and the upper frame 32. A recessed portion 45a and a bulging portion 45b are formed in the engaging portion 45. In other words, the recessed portion 45a and the bulging portion 45b form an engaging groove that can be engaged with the left and right side frames 31 and the upper frame 32.

[0113] <Manufacturing method of headrest 3>

[0114] Next, refer to Figures 7 to 11 A manufacturing process of the headrest 3 including the headrest pad 40 will be described.

[0115] like Figure 7 and Figure 8As shown, first, the inner headrest pad 41 is installed on the headrest pillar 30. In detail, the bulging portion 45b formed on the mounting portion 44 of the inner headrest pad 41 is pressed from left and right, so that the bulging portion 45b is deformed to pass through between the left and right side frames 31. Next, the bulging portion 45b is inserted between the left and right side frames 31 and positioned so that the supported surface 44a of the mounting portion 44 abuts against the support plate 33. Finally, the inner headrest pad 41 is pushed into the headrest pillar 30 so that the left and right side frames 31 and the upper frame 32 are fitted into the recessed portion 45a of the engaging portion 45. As a result, Figure 8 As shown, the installation of the inner headrest pad 41 with respect to the headrest pillar 30 is completed.

[0116] At this time, if Fig. 9 As shown, the interval W1 of the recessed portion 45a in the seat width direction has a size substantially equal to the interval between the inner sides of the left and right side frames 31. On the other hand, the bulging portion 45b bulges outwardly in the seat width direction relative to the recessed portion 45a, and the interval W2 of the bulging portion 45b in the seat width direction is larger than the interval between the inner sides of the left and right side frames 31. In other words, the engaging portion 45 exists in a manner overlapping with the left and right side frames 31 and the upper frame 32 in the front-rear direction orthogonal to the front surface 42c (support surface) of the main body 42. Therefore, it is possible to prevent the engaging state of the engaging portion 45 and the headrest pillar 30 from being released unintentionally.

[0117] In addition, if Figure 8 As shown, when the inner headrest pad 41 is mounted on the headrest pillar 30, the mounting portion 44 is supported so as to be accommodated in the support plate 33. Therefore, the inner headrest pad 41 can be positioned and supported on the headrest pillar 30 more appropriately.

[0118] Here, a gap G is formed between the left and right side frames 31 and the upper frame 32 and the support plate 33 (see Figure 7 ). In other words, the support plate 33 is installed at a position away from the side frame 31 in a direction farther from the front surface 42c than the side frame 31. As a result, the inner headrest pad 41 can be stably installed on the headrest pillar 30, and the dimension of the inner headrest pad 41 in the front-rear direction can be increased, thereby improving the impact absorption capacity of the headrest 3.

[0119] Next, if Fig.10 As shown, the headrest pillar 30 and the inner headrest pad 41 are covered by the trim cover 3a and accommodated in the accommodation space S inside the trim cover 3a. In preparation for injecting the stock solution of unfoamed foamed polyurethane into the inner side of the trim cover 3a, the headrest 3 is turned over so that its vertical direction is opposite.

[0120] Next, the unfoamed foamed polyurethane stock solution is injected from the spray nozzle N and guided by the guide groove 43 formed in the inner headrest pad 41, and the storage space S is filled with the stock solution. To explain in detail, first, the spray nozzle N is inserted into the nozzle insertion hole 3a1 formed in the decorative cover 3a, and the foamed polyurethane stock solution is injected. The nozzle insertion hole 3a1 is formed in the center of the seat width direction. Similarly, the guide groove 43 is also formed in the center of the seat width direction. Therefore, as Fig.11 As shown by the arrow F, the stock solution of the foamed polyurethane sprayed from the spray nozzle N is first guided by the lower surface guide groove 43a in a manner of flowing forward along the lower surface 42b of the main body 42. Thereafter, the stock solution is guided by the front surface guide groove 43b in a manner of flowing downward along the front surface 42c. The lower surface guide groove 43a and the front surface guide groove 43b are connected at the connecting edge 42c1 where the lower surface 42b and the front surface 42c are connected. Therefore, the stock solution of the foamed polyurethane flows down along the lower surface 42b and the front surface 42c of the main body 42 of the inner headrest pad 41, thereby quickly and accurately filling the inner side of the decorative cover 3a.

[0121] Then, the unfoamed stock solution of the foamed polyurethane filling the accommodation space S is foamed, thereby forming the outer headrest pad 46. To explain in detail, first, the ejection nozzle N is pulled out from the nozzle insertion hole 3a1. Then, the stock solution of the foamed polyurethane expands and foams so as to press the decorative cover 3a from the inside toward the outside. Therefore, the stock solution is formed into the same shape as the accommodation space S formed inside the decorative cover 3a by foaming, thereby forming the outer headrest pad 46. Finally, the nozzle insertion hole 3a1 is sutured and closed.

[0122] When the production of the headrest 3 is completed as described above, the headrest stay 30 is mounted on the headrest guide 21 c 1 provided on the back frame 20 , whereby the headrest 3 is mounted on the seat back 2 .

[0123] As described above, the headrest pad 40 includes: the inner headrest pad 41, which is mounted on the headrest pillar 30; and the outer headrest pad 46, which covers the inner headrest pad 41 and is made of foamed polyurethane. In addition, the guide groove 43 for guiding the raw liquid of the unfoamed foamed polyurethane is formed in the inner headrest pad 41. As a result, the storage space S inside the decorative cover 3a is filled with the raw liquid of the foamed polyurethane in advance, so that the outer headrest pad 46 can be prevented from being insufficient in thickness or uneven in density, and the manufacturing process of the headrest 3 can be made more efficient.

[0124] <Modification>

[0125] The vehicle seat S1 according to one embodiment of the present invention has been described above, but the above embodiment is only an example for facilitating understanding of the present invention and does not limit the present invention. Figure 12 to Figure 14 A headrest 3A according to a modified example will be described.

[0126] In the above-described embodiment, the support plate 33 is described as being attached to a position away from the side frame 31 in a direction farther away from the front surface 42 c than the side frame 31 , but the present invention is not limited thereto.

[0127] Figure 12 to Figure 14 30A and an inner headrest pad 41A of a modified example are shown. Fig.12 As shown, the support plate 33A of the headrest pillar 30A of the modified example is attached to a position away from the side frame 31 in a direction closer to the front surface 42 c than the side frame 31 .

[0128] The inner headrest pad 41A of the modified example includes a main body portion 42A having a substantially rectangular parallelepiped shape and an attachment portion 44A protruding from the main body portion 42A toward the rear of the seat. The main body portion 42A and the attachment portion 44A are integrally formed.

[0129] The main body 42A has an upper surface 42a, a lower surface 42b, a front surface 42c, a rear surface 42d, and side surfaces 42e. The rear surface 42d is formed with a fitting recess 42f that fits with the support plate 33A.

[0130] In addition, although Figure 12 to Figure 14 Although not shown in the figure, guide grooves 43 are formed on the lower surface 42b and the front surface 42c in the same manner as in the above embodiment. That is, the guide grooves 43 are formed at positions different from the fitting recess 42f. Thus, the inner headrest pad 41 can be accurately fitted into the headrest pillar 30.

[0131] The mounting portion 44A extends rearward from the outer periphery of the rear surface 42d of the main body 42A. The mounting portion 44A has an outer side surface 44b1 formed flush with the upper surface 42a and the side surface 42e of the main body 42A, and an inner side surface 44b2 formed with an engaging portion 45A engaged with the side frame 31 and the upper frame 32. The engaging portion 45A has a recessed portion 45a and a bulging portion 45b. In other words, the recessed portion 45a and the bulging portion 45b form an engaging groove in which the side frame 31 and the upper frame 32 can be engaged.

[0132] Next, the mounting operation of the inner headrest pad 41A according to the modified example to the headrest pillar 30A will be described.

[0133] When installing the inner headrest pad 41A on the headrest pillar 30A, first, position the inner headrest pad 41A above the headrest pillar 30A and align the left and right side frames 31 with the left and right recesses 45a in an up-and-down manner. Next, shift the inner headrest pad 41A relative to the headrest pillar 30A in a manner that the left and right recesses 45a descend along the left and right side frames 31. Finally, push the inner headrest pad 41A into the headrest pillar 30A so that the upper frame 32 fits into the recess 45a of the locking portion 45. At this time, the support plate 33A is accommodated in the fitting recess 42f. Thus, as shown in FIG. Fig.13 As shown in FIG. 1 , the mounting operation of the inner headrest pad 41A to the headrest pillar 30A is completed.

[0134] At this time, if Fig.14 As shown, the interval W3 of the recessed portion 45a in the seat width direction has a size that is substantially equal to the interval between the outer sides of the left and right side frames 31. On the other hand, the bulging portion 45b bulges inwardly in the seat width direction relative to the recessed portion 45a. The interval W4 of the bulging portion 45b in the seat width direction has a size that is smaller than the interval between the outer sides of the left and right side frames 31. In other words, the engaging portion 45 exists in a manner that overlaps with the left and right side frames 31 and the upper frame 32 in the front-to-back direction orthogonal to the front surface 42c (support surface). Therefore, it is possible to prevent the engaging state of the engaging portion 45A and the headrest pillar 30A from being accidentally released.

[0135] In addition, the inner headrest pad 41A is attached and engaged so as to wrap the headrest pillar 30A from the outside. Therefore, compared with the above-described embodiment, the inner headrest pad 41A can be appropriately positioned and supported with respect to the headrest pillar 30A.

[0136] The headrest 3A of the modified example has been described above. In the above, the headrest 3 is cited as an example as a support member for supporting the seated person, but the support member is not limited to the headrest 3. The present invention can also be applied to support members other than the headrest 3, such as the armrest 5 or the auxiliary headrest 4.

[0137] In the above embodiment, the inner headrest pad 41 is a molded body of foamed polypropylene and the outer headrest pad 46 is a molded body of foamed polyurethane, but the present invention is not limited thereto. The inner headrest pad 41 and the outer headrest pad 46 may be resin molded bodies that can support the load of the seated person and provide comfort to the seated person.

[0138] In the above embodiment, the inner headrest pad 41 and the outer headrest pad 46 have different hardnesses (deformation amounts relative to loads), but the present invention is not limited thereto. By combining a plurality of pads, it is possible to provide the best seating performance including safety by providing diversity and flexibility in the pad characteristics.

[0139] About reference Figures 1 to 14 The described embodiment further discloses the following supplementary notes.

[0140] (Note 1)

[0141] A method for manufacturing a vehicle seat, comprising:

[0142] mounting a first pad on a frame forming a skeleton of the support member;

[0143] Covering the frame and the first pad with a decorative cover;

[0144] injecting a liquid body of an unfoamed foamable resin, and guiding the liquid body by a guide portion formed on the first gasket so as to fill the inner side of the decorative cover; and

[0145] The second gasket covering the first gasket is formed by foaming the unfoamed foamable resin.

[0146] (Note 2)

[0147] The method for manufacturing a vehicle seat according to Supplement 1, wherein the first cushion comprises: a support surface for supporting the seated person; and a mounting portion protruding in a direction perpendicular to the support surface and having an engaging portion for engaging with the frame,

[0148] The operation of mounting the first gasket on the frame includes mounting the first gasket on the frame by engaging the engaging portion with the frame.

[0149] (Note 3)

[0150] According to the method for manufacturing a vehicle seat according to Supplement 2, the operation of installing the first pad on the frame includes: the engaging portion is installed on the frame in a manner that overlaps with the frame in a direction orthogonal to the support surface.

[0151] (Note 4)

[0152] The method for manufacturing a vehicle seat according to Supplementary Note 1, wherein the support member is a headrest for supporting the seated person's head, the method further comprising:

[0153] The frame is fixed to a seat back supporting the back of the seated person.

[0154] According to the method for manufacturing a vehicle seat, the trim cover can be filled in advance with the stock solution of the unfoamed foamable resin, thereby preventing the outer pad from having insufficient thickness or uneven density and achieving efficiency in the manufacturing process of the support member.

[0155] Furthermore, since the first gasket has the mounting portion formed with the engaging portion to be engaged with the frame, the first gasket can be easily mounted on the frame, and the manufacturing process of the supporting member can be made more efficient.

[0156] Furthermore, since the engaging portion is formed at a position overlapping with the frame in the front-rear direction, it is possible to suppress the engaging state between the engaging portion and the frame from being released due to the load of the seated person.

[0157] Description of Figure Numbers

[0158] S1: Vehicle seats

[0159] F1: Seat frame

[0160] 1: Seat cushion

[0161] 1a: Pad

[0162] 1b: Decorative cover

[0163] 2: Seat back

[0164] 2a: Pad

[0165] 2b: Decorative cover

[0166] 3: Headrest (supporting member)

[0167] 3a: Decorative cover

[0168] 3a1: Nozzle insertion hole

[0169] 4: Auxiliary headrest

[0170] 4a: Decorative cover

[0171] 4b: Auxiliary headrest support

[0172] 5: Handrails

[0173] 5a: Armrest padding

[0174] 5b: Decorative cover

[0175] 5c: Handrail frame

[0176] 5d: Base frame

[0177] 6: Electrical parts

[0178] 10: Seat frame

[0179] 11: Side frame

[0180] 12: Front frame

[0181] 13: Rear frame

[0182] 14: Disc frame

[0183] 15: Compression member

[0184] 16: Seat rotation device

[0185] 17: Support feet

[0186] 20: Backrest frame

[0187] 21: Main frame

[0188] 21a, 21b: Side frame

[0189] 21c: Upper frame

[0190] 21c1: Headrest guide

[0191] 21d: Lower frame

[0192] 22: Subframe

[0193] 22a: Horizontal subframe

[0194] 22b: Vertical subframe

[0195] 23: Panel frame

[0196] 23a, 23b: Reinforced convex part

[0197] 23c: Strengthen the stalk

[0198] 24: Linking Frames

[0199] 25A, 25B: Strengthening bracket

[0200] 26: Damper component

[0201] 27: Arm connecting bracket

[0202] 28: Seat cushion connecting bracket

[0203] 29: Base connecting bracket

[0204] 30, 30A: Headrest support (frame)

[0205] 31: Side frame (parallel frame)

[0206] 32: Upper frame (connecting frame)

[0207] 33, 33A: Support plate

[0208] 33a: Flat part

[0209] 33b: Bend

[0210] 40: Headrest padding (pad)

[0211] 41, 41A: Inner headrest pad (first pad)

[0212] 42, 42A: Main body

[0213] 42a: Upper surface

[0214] 42b: Lower surface

[0215] 42c: front surface

[0216] 42c1: Connecting Edges

[0217] 42d: rear surface

[0218] 42e: Side

[0219] 42f: Fitting recess

[0220] 43: Boot slot

[0221] 43a: Lower surface guide groove (first guide groove portion)

[0222] 43a1: Central Department

[0223] 43a2: Side wall

[0224] 43b: front surface guide groove (second guide groove portion)

[0225] 43b1: Central

[0226] 43b2: Side wall

[0227] 44, 44A: Installation

[0228] 44a: Supported surface

[0229] 44b: Installation side

[0230] 44b1: Outside side

[0231] 44b2: Inside side

[0232] 45, 45A: snap-fit ​​part

[0233] 45a: concave part

[0234] 45b: bulge

[0235] 46: Outer headrest pad (second pad)

[0236] 50: Switching device

[0237] 51: Locking component

[0238] 52: Backrest operating lever

[0239] 53: Linking Cables

[0240] 54: Impactor

[0241] G: Gap

[0242] N: Spray nozzle

[0243] S: Containment Space

Claims

1. A vehicle seat, comprising a support member for supporting a seated person, wherein the vehicle seat is characterized in that: The supporting member comprises: a frame forming a skeleton of the supporting member; and a pad covering the frame. The pad includes: a first pad mounted on the frame; and a second pad covering the first pad and containing a foaming resin. The first gasket includes a guide portion that guides the liquid of the unfoamed foamable resin.

2. The vehicle seat according to claim 1, characterized in that: The guide portion is a guide groove extending in a direction away from a position where the liquid of the foamable resin is injected.

3. The vehicle seat according to claim 2, characterized in that: The guide groove is deepest at the center in the seat width direction and becomes shallower as it moves away from the center in the seat width direction.

4. The vehicle seat according to claim 2, characterized in that: The guide groove has a triangular pyramid shape.

5. The vehicle seat according to claim 2, characterized in that: The first pad includes: a first surface facing the discharge nozzle that discharges the liquid; and a second surface intersecting the first surface and allowing the liquid to flow downward. The guide groove is formed across the first surface and the second surface, and has: a first guide groove portion formed on the first surface; and a second guide groove portion formed on the second surface.

6. The vehicle seat according to claim 5, characterized in that: The first pad has a connecting edge, and the connecting edge connects the first surface and the second surface to each other. The first guide groove portion and the second guide groove portion are connected to each other at the connecting edge.

7. The vehicle seat according to claim 1, characterized in that: The first gasket is formed with a fitting recess to be fitted with the frame. The guide portion is formed at a position different from that of the fitting recess.

8. The vehicle seat according to claim 1, characterized in that: The supporting member is a headrest for supporting the head of the seated person. The first cushion includes a support surface for supporting the seated person and a mounting portion that protrudes in a direction perpendicular to the support surface and is formed with an engaging portion that engages with the frame.

9. The vehicle seat according to claim 8, characterized in that: The frame comprises: a pair of parallel frames located at both ends in the seat width direction or both ends in the up-down direction and extending parallel to each other; and a connecting frame connecting the pair of parallel frames at the ends in the length direction of the pair of parallel frames. The engaging portion is formed at a position overlapping the connecting frame in a direction perpendicular to the supporting surface.

10. The vehicle seat according to claim 9, characterized in that: The engaging portion is formed at a position overlapping the parallel frame in a direction perpendicular to the supporting surface.

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