Seat and method for manufacturing the seat

Abstract

The objective is to provide a seat that improves machinability when fixing a back panel and a trim to the rear of a backrest. A backrest (1) comprises a cover element (3) covering a front surface and side surfaces of a frame (2), a back panel (5) covering a rear surface of the frame (2), a trim (4) covering a rear surface of the back panel (5), and a first engagement element (7). The cover element (3) has a trim fixing part (3d). The trim (4) has a main part (4a) covering the back panel (5) and a pair of extension parts (4c) extending outwards in a width direction of the main part (4a). The extension part (4c) extends and is rotated towards a front of the back panel (5) so that it is positioned between the back panel (5) and the trim fixing part (3d).The first engagement element (7) fixes the extension part (4c) to the cladding fixing part (3d) by passing through the extension part (4c) and by engaging with the cladding fixing part (3d).

Description

Sheet and method for manufacturing the sheet

[0001] The present invention relates to a seat having a seat back.

[0002] Conventionally, seats installed in vehicles such as automobiles generally have a structure with a seat back that supports the back of the seated occupant. The rear portion of the seat back is composed of a backboard fixed to the rear side of the frame inside the seat and a rear trim that is a surface covering the rear of the backboard.

[0003] The rear trim is usually attached to cover the outer surface of the backboard after the backboard is installed. In conventional seats, the rear trim is generally fixed to the side trim, which is the surface that forms the outer surface of the seat, using fasteners. The fasteners are attached by sewing along the opposing edges of the rear trim and the side trim. After the backboard is installed, the rear trim is fixed to the side trim by closing the fasteners.

[0004] However, manufacturing a seat with the above-mentioned fasteners requires a process of sewing the fasteners along the edges of the rear trim and the side trim, a process of attaching the backboard to the frame using clips or the like, and a process of fixing the rear trim to the side trim using fasteners. This requires many work steps in seat manufacturing, and also requires the use of separate parts to fix the backboard and the rear trim, making it difficult to reduce manufacturing costs.

[0005] Furthermore, structures described in Patent Documents 1 and 2 are known as seats having a structure for fixing the back trim without using fasteners. In both of these structures, a sheet-like member corresponding to the back trim is fixed to the backboard using clips. Specifically, in the structure described in Patent Document 1, a folded portion of the carpet is fixed to the backboard at the lower part of the back of the seat with clips. In addition, in the structure described in Patent Document 2, the upholstery is fixed on the back side of the seat by being fitted into a fitting hole in the backboard with clips.

[0006] However, in both of the structures described in Patent Documents 1 and 2 above, the rear trim is fixed to the backboard with clips instead of fasteners, but separate parts and separate work are required to fix the backboard to a frame, etc., and this is still not sufficient in terms of improving workability.

[0007] Patent No. 5387635 Japanese Patent Application Laid-open No. 8-256874

[0008] The present invention has been made in view of the above circumstances, and aims to provide a seat that can improve the workability in fixing the backboard and the cover on the rear side of the seat back.

[0009] In order to solve the above-mentioned problems, the seat of the present invention is a seat having a seat back, wherein the seat back comprises a frame that forms the skeleton of the seat back, a cover member that covers the front surface of the frame, a backboard that covers the back surface of the frame, a skin that covers the back surface of the backboard, and a first fastening device that secures the skin to the cover member, wherein the cover member has a front surface portion that covers the front surface of the frame, a pair of side surfaces that cover both side surfaces of the frame, and a skin fixing part that is disposed in a space formed by the front surface portion and the pair of side surfaces and has a first engagement hole that can engage with the first fastening device, and the skin has a main body portion that covers the back side of the backboard, and an extension portion that wraps around from the periphery of the main body portion to the front side of the backboard and is interposed between the backboard and the skin fixing part, and the first fastening device penetrates the extension portion and is engaged with the first engagement hole of the skin fixing part, thereby securing the extension portion to the skin fixing part.

[0010] 1 is a perspective view showing the overall configuration of a seat back in a seat according to an embodiment of the present invention. It is an exploded perspective view of the seat back of FIG. 1. It is a perspective view of the cover member of FIG. 2 as seen from the rear side and diagonally from the upper right. It is a view of the cover member of FIG. 2 as seen from the rear side. It is a plan view of the cover member of FIG. 2. It is an explanatory view showing a manufacturing method of the seat back of FIG. 2, showing a state before a pair of reinforcing plates of FIG. 2 are sewn to a pair of extensions of the rear trim. It is an explanatory view showing a manufacturing method of the seat back of FIG. 2, showing a state after the pair of reinforcing plates of FIG. 2 are sewn to a pair of extensions of the rear trim. It is an explanatory view showing a manufacturing method of the seat back of FIG. 2, showing a state after a first clip has penetrated the reinforcing plates and the extensions of the rear trim from the front side and a second clip has penetrated from the rear side of the backboard. It is an explanatory view showing a manufacturing method of the seat back of FIG. 2, showing a state in the middle of bending the extensions of the rear trim forward to wrap around the backboard. 1. An explanatory diagram showing a manufacturing method for the seat back of FIG. 2, illustrating a state after the extension of the back trim has been brought around to the front side and the backboard has been rolled up, the reinforcing plate is overlapped on the front surface of the backboard, and the reinforcing plate extension is engaged with the front surface of the backboard by the second clip. 2. An explanatory diagram showing a manufacturing method for the seat back of FIG. 2, illustrating a state in the middle of engaging the first clip with the first engagement hole of the upholstery fixing portion of the cover member and engaging the second clip with the second engagement hole of the frame. 3. An explanatory diagram showing a manufacturing method for the seat back of FIG. 2, illustrating a state after the first clip has been engaged with the first engagement hole of the upholstery fixing portion of the cover member and the second clip has been engaged with the second engagement hole of the frame, i.e., a completed seat back. 4. An exploded perspective view of a seat back having no second clip and no reinforcing plate extension according to a modified example of the seat of the present invention. 5. An explanatory diagram showing a manufacturing method for the seat back of FIG. 13, illustrating a state in which the first clip has penetrated the reinforcing plate and the extension of the back trim from the front side. 14 is an explanatory diagram showing a manufacturing method of the seat back of FIG. 13, illustrating a state in which the extension portion of the rear trim is being bent forward to wrap around the back board. FIG.19 is an explanatory diagram showing a manufacturing method of the seat back of FIG. 13, showing a state after the extension of the back trim has been brought around to the front side and the backboard has been rolled up, and showing a state in which the reinforcing plate is superimposed on the front surface of the backboard. 19 is an explanatory diagram showing a manufacturing method of the seat back of FIG. 13, showing a state in which the first clip is in the middle of being engaged with the first engagement hole of the upholstery fixing portion of the cover member. 19 is an explanatory diagram showing a manufacturing method of the seat back of FIG. 13, showing a state after the first clip has been engaged with the first engagement hole of the upholstery fixing portion of the cover member, i.e., a state in which the seat back is completed. 19 is an explanatory diagram showing a manufacturing method of a seat back according to another modification of the seat of the present invention, showing a state in which the extension of the back trim is in the middle of being brought around the backboard having a protrusion, and just before the reinforcing plate extension is engaged with the protrusion of the backboard. 19 is an explanatory diagram showing a state after the first clip has been engaged with the first engagement hole of the upholstery fixing portion of the cover member, i.e., a state in which the seat back is completed.

[0011] Hereinafter, a seat according to an embodiment of the present invention will be described in detail with reference to the drawings.

[0012] As shown in FIG. 1, a seat according to an embodiment of the present invention includes a seat back 1 (backrest) that supports the back of a seated occupant, and a seat cushion (not shown) that supports the buttocks of the seated occupant.

[0013] The seat back 1 shown in FIG. 1 is an example of a seat back for a middle seat in a three-seater seat in the rear of a vehicle. The seat back 1 has a generally rectangular parallelepiped shape and an exterior width sufficient to support the back in the width direction Y. An upper back cushion C1 and other components that support the upper back of a seated occupant are disposed on the upper side of the seat back 1, and a front cushion C2 and other components are disposed on the front side X1 of the seat back 1. The front cushion C2 can be moved between an upright position along the front of the seat back 1 and a reclined position toward the forward side X1. When in the upright position, the front cushion C2 can support the back of the seated occupant, and when reclined toward the forward side X1, it can also be used as an armrest.

[0014] In the drawings used in this embodiment, the front-to-rear direction of the seat back 1 is indicated by arrow X (front side (front face) X1, rear side (back face) X2), the width direction is indicated by arrow Y, and the up-down direction is indicated by arrow Z.

[0015] 1 and 2, the seat back 1 includes a vertical frame 2 that forms the framework of the seat back 1, a cover member 3 that covers a front surface 2b and both side surfaces 2c of the frame 2, a backboard 5 that covers a back surface 2d of the frame 2, a back trim 4 that is a surface covering a back surface 5c of the backboard 5, a plurality of (six in this embodiment) first clips 7 that are first fastening devices that fasten the back trim 4 to the cover member 3 (specifically, a trim fastening portion 3d described below), and a plurality of (two in this embodiment) second clips 17 that are second fastening devices that fasten the backboard 5 to the frame 2. In this embodiment, the back trim 4 has a pair of reinforcing plates 6 that serve as reinforcing portions that reinforce a pair of extension portions 4c of the back trim 4, which will be described below.

[0016] The frame 2 in this embodiment is a vertical rectangular frame having the front surface 2 b, both side surfaces 2 c, and a back surface 2 d. The frame 2 has a pair of second engagement holes 2 a spaced apart in the width direction Y in the lower beam portion, which are engageable with the second clips 17.

[0017] 2 to 5, the cover member 3 has a front portion 3a that covers the front surface 2b of the frame 2, and a pair of side portions 3b that extend from both edges of the front portion 3a toward the rear side X2 and cover both side surfaces 2c of the frame 2. Therefore, the cover member 3 has a space 3c that is open to the rear side X2 and is formed by the front portion 3a and the pair of side portions 3b (see FIGS. 2 and 3 and 5).

[0018] The cover member 3 further has a plurality of (six in this embodiment) trim fixing portions 3d (skin fixing portions) that are disposed within the space 3c and to which the rear trim 4 is fixed. In this embodiment, three trim fixing portions 3d are provided on each of the opposing inner surfaces of the pair of side portions 3b.

[0019] Each trim fixing portion 3d has an abutment surface 3f facing the rear side X2 of the cover member 3 and a first engagement hole 3e formed on the abutment surface 3f and capable of engaging with the first clip 7.

[0020] 2, the backboard 5 is a rectangular plate-like member large enough to cover the back surface 2d of the frame 2. A pair of through holes 5a is formed in the lower end of the backboard 5 at positions corresponding to the pair of second engagement holes 2a of the frame 2. The backboard 5 is made of a material that is rigid enough not to be dented even when the legs of a seated person hit it, such as a corrugated plastic plate or a thick plastic plate.

[0021] 2 and 6, the rear trim 4 is a thin, sheet-like member that includes a rectangular main body 4a large enough to cover the rear side X2 of the backboard 5 (the same dimensions as or slightly larger than the backboard 5), a lower band 4b extending downward from the main body 4a, and a pair of extensions 4c. The rear trim 4 may be any flexible, thin, sheet-like member, and may be made from natural leather, synthetic leather, synthetic resin material, or the like. The lower band 4b is fixed to the lower end of the frame 2 or another predetermined mounting position, and is not an essential component of the present invention, so it may be omitted.

[0022] The pair of extensions 4c extend from both side edges of the main body 4a in the width direction Y to the outside of the main body 4a in the width direction Y. The width (length in the width direction Y) of the extensions 4c is large enough to wrap around the front side X1 of the backboard 5 superimposed on the main body 4a and wrap around the side edges of the backboard 5.

[0023] The pair of extensions 4c have through holes 4d formed at positions corresponding to the height of the first engagement holes 3e of the six trim fixing portions 3d of the cover member 3. The through holes 4d are arranged at positions that coincide with the positions of the first engagement holes 3e of the trim fixing portions 3d of the cover member 3 when the extensions 4c have wrapped around the side edges of the backboard 5 as shown in Figures 8 and 11.

[0024] 2 and 6, the rear trim 4 of this embodiment has a pair of reinforcing plates 6 as a reinforcing portion that reinforces the area around the through-hole 4d in the pair of extensions 4c through which the first clip 7 passes. That is, the reinforcing portion of this embodiment is formed by the pair of reinforcing plates 6 that are fixed to the front surfaces 4c1 of the pair of extensions 4c, thereby reinforcing the extensions 4c.

[0025] The reinforcing plate 6 is preferably made of a lightweight material that has both adequate rigidity to reinforce the extension portion 4c and adequate elasticity to allow the extension portion 4c to be easily fitted around it. For example, a thin plate made of a synthetic resin such as polypropylene (PP) is used, but various materials such as thin metal plate or cardboard can be used as long as they have at least the above-mentioned rigidity.

[0026] The reinforcing plate 6 is fixed to the extension 4c by sewing (see sewn portion 8 in FIG. 7) or the like, but may be fixed by other fixing methods such as adhesive.

[0027] The specific configuration of the reinforcing plate 6 is a reinforcing plate main body portion 6a having approximately the same dimensions as the extension portion 4c and overlapping the extension portion 4c in the front-to-back direction X, and a reinforcing plate extension portion 6b extending in the width direction Y from the reinforcing plate main body portion 6a to a position where it does not overlap with the extension portion 4c.

[0028] The reinforcing plate main body 6a is formed with three through holes 6c at positions corresponding to the three through holes 4d of the extension 4c.

[0029] The reinforcing plate extension 6b has a configuration that allows it to be fixed to the front surface 5d of the backboard 5. Specifically, the reinforcing plate extension 6b has third engagement holes 6d that are through holes with which the second clips 17 can engage in order to fix the reinforcing plate extension 6b to the front surface 5d of the backboard 5. The third engagement holes 6d are disposed at positions corresponding to the height of the pair of second engagement holes 2a of the frame 2. More specifically, the third engagement holes 6d are disposed at positions that coincide with the positions of the through holes 5a of the backboard 5 when the extension 4c of the rear trim 4 shown in Figures 8 and 10 has wrapped around the front side X1 of the backboard 5 and wrapped around the side edge of the backboard 5.

[0030] As shown in Figure 2, the first clip 7 is a member that fixes the extension portion 4c of the rear trim 4 and the reinforcing plate 6 to the trim fixing portion 3d of the cover member 3, and is made of, for example, an inexpensive plastic clip.

[0031] The second clips 17 are members that fix the backboard 5 and the reinforcing plate 6 to the rear surface 2d of the frame 2, and are made of, for example, an inexpensive resin clip.

[0032] The above-described components of the seat back 1 shown in FIGS. 1 to 7 are assembled as shown in FIG.

[0033] 12, the pair of extensions 4c of the rear trim 4 are bent toward the front side X1 of the backboard 5 and wrap around the front side X1 of the backboard 5. In this state, the pair of extensions 4c are interposed between the backboard 5 and the trim fixing portion 3d. The pair of reinforcing plates 6 are overlapped on the front side X1 of the backboard 5.

[0034] The first clip 7 penetrates the extension 4c and the reinforcing plate 6, and the tip of the first clip 7 is engaged with the first engagement hole 3e of the trim fixing portion 3d. As a result, the pair of extensions 4c of the rear trim 4 are fixed to the trim fixing portion 3d in a state of abutting against the abutment surface 3f of the trim fixing portion 3d.

[0035] The second clip 17 penetrates the backboard 5 and the third engagement hole 6d of the reinforcing plate extension 6b to engage the reinforcing plate extension 6b with the front surface 5d of the backboard 5, and is also engaged with the second engagement hole 2a of the frame 2, thereby fixing the backboard 5 together with the reinforcing plate 6 to the frame 2.

[0036] (Method of Manufacturing Seat Back 1) The seat back 1 configured as above is specifically manufactured in the following procedure.

[0037] 6 and 7, the reinforcing plate body portions 6a of the pair of reinforcing plates 6 are overlapped with the pair of extension portions 4c of the back trim 4 and sewn together in the vertical direction Z to form the sewn portions 8. When sewing, the positions of the through holes 6c of the reinforcing plate body portions 6a and the through holes 4d of the extension portions 4c are aligned.

[0038] 8, the second clips 17 are inserted from the rear side X2 into the pair of through holes 5a in the backboard 5, penetrating the backboard 5. The first clips 7 are then inserted from the front side X1 into the through holes 6c in the reinforcing plate main body 6a and the through holes 4d in the extension 4c, penetrating the reinforcing plate 6 and the extension 4c. The main body 4a of the rear trim 4 is then superimposed on the backboard 5 from the rear side X2.

[0039] 8 to 10 , the pair of extensions 4c of the rear trim 4 are brought around the front side X1 to combine the rear trim 4 and the backboard 5. Specifically, the pair of extensions 4c are folded back so as to wrap around both side edges of the backboard 5, and the pair of reinforcing plates 6 are overlapped on the front surface 5d of the backboard 5. At the same time, the second clips 17 are passed through the third engagement holes 6d of the reinforcing plate extensions 6b to engage the reinforcing plate extensions 6b with the front surface 5d of the backboard 5. Furthermore, as the extensions 4c are brought around the front side X1 of the backboard 5, the first clips 7 are positioned on the front surface X1 of the backboard 5.

[0040] In addition, in Figures 8 to 12, the rear trim 4, backboard 5, and reinforcing plate 6 are shown slightly spaced apart for ease of viewing, but in reality, they are in close contact with each other.

[0041] 11 and 12, the combined rear trim 4 and back board 5, formed by wrapping the pair of extensions 4c of the rear trim 4 around both side edges of the back board 5, are brought close to the frame 2 and trim fixing portion 3d arranged in the space 3c of the cover member 3 from the rear side X2, and the first clip 7 is engaged with the first engaging hole 3e of the trim fixing portion 3d of the cover member 3. At the same time, the second clip 17 is engaged with the second engaging hole 2a of the frame 2. This makes it possible to simultaneously fix the rear trim 4 and back board 5 to the cover member 3 and the frame 2. In this manner, the seat back 1 having the structure shown in FIG. 12 is completed.

[0042] 2 and 12, in the seat of this embodiment, the rear trim 4 covering the rear side X2 of the backboard 5 of the seat back 1 has a main body 4a covering the rear side X2 of the backboard 5 and a pair of extensions 4c extending from the periphery of the main body 4a around to the front side X1 of the backboard 5 and interposed between the backboard 5 and the trim fixing portion 3d (skin fixing portion). Therefore, the rear trim 4 and the backboard 5 are joined together using the pair of extensions 4c, making it possible to simultaneously attach the rear trim 4 and the backboard 5.

[0043] That is, when manufacturing the above-described seat back 1, the rear trim 4 and the back board 5 can be combined together with the reinforcing plate 6 by wrapping the pair of extensions 4c around the front side X1 of the back board 5. Then, the first clip 7 penetrates the extensions 4c and the reinforcing plate 6 and engages with the first engagement hole 3e of the trim fixing portion 3d of the cover member 3, thereby fixing the extensions 4c to the trim fixing portion 3d. This makes it possible to simultaneously fix the rear trim 4 and the back board 5 to the trim fixing portion 3d of the cover member 3. As a result, it is possible to improve the workability of the work of fixing the back board 5 and the rear trim 4 on the rear side X2 of the seat back 1.

[0044] Furthermore, in the seat back 1 configured as described above, fasteners are not required to assemble the backboard 5 and the rear trim 4 in the seat back 1, and the backboard 5 and the rear trim 4 can be simultaneously secured using inexpensive resin clips as the first clips 7. Therefore, fasteners are eliminated from the exterior of the seat, improving the appearance of the seat back 1. Furthermore, since the backboard 5 and the rear trim 4 are simultaneously secured using inexpensive resin clips (first clips 7), manufacturing costs can also be reduced. In particular, in the seat back 1 described above, the rear trim 4 and the backboard 5 can be simultaneously secured to the cover member 3 by the simple operation of simply engaging the first clips 7 with the first engagement holes 3e of the trim securing portions 3d of the cover member 3. This eliminates the need for the complicated sewing process required to attach fasteners to the rear trim 4 in conventional seat manufacturing, which is highly advantageous in terms of reducing manufacturing costs.

[0045] Furthermore, because the extension 4c of the rear trim 4 is reinforced by the reinforcing plate 6, there is no risk of the extension 4c fixed by the first clip 7 breaking around the through-hole 4d. Moreover, since wrinkles and distortions do not occur in the extension 4c and its surrounding area after it has been fixed by the first clip 7, the appearance of the rear trim 4 is improved.

[0046] (2) In the seat of this embodiment, the rear trim 4 has a pair of reinforcing plates 6 as a reinforcing portion that reinforces at least the portion of the extension 4c around the through hole 4d through which the first clip 7 passes. This prevents the through hole 4d from being stretched by the first clip 7.

[0047] In this embodiment, the extension 4c can be reinforced by fixing a reinforcing plate 6 to the front surface 4c1 of the extension 4c. The entire extension 4c can be easily and reliably reinforced by using the reinforcing plate 6. Furthermore, the reinforcing plate 6 can reliably straighten the folded portion of the extension 4c, improving the appearance of the rear trim 4.

[0048] Furthermore, since the stiffness of the reinforcing plate 6 is higher than the stiffness of the extension 4c, the extension 4c can be easily folded back at the location of the reinforcing plate 6. Therefore, the backboard 5 can be easily rolled up by the extension 4c.

[0049] In this embodiment, the reinforcing plate 6 fixed to the front surface 4c1 of the extension 4c is used as an example of a reinforcing part that reinforces the extension 4c, but the present invention is not limited to this, and any reinforcing part other than the reinforcing plate 6 may be used as long as it reinforces at least the portion of the extension 4c around the portion (through hole 4d) through which the first clip 7 passes. For example, other reinforcing parts may be metal rings (grommets) fitted around the through hole 4d of the extension 4c, or resin layers or adhesive layers that are impregnated and hardened around the portion of the extension 4c around the through hole 4d.

[0050] (3) In the seat of this embodiment, as shown in Figures 6 to 7 and 10, the reinforcing plate 6 has a reinforcing plate main body 6a that overlaps the extension 4c, and a reinforcing plate extension 6b that extends from the reinforcing plate main body 6a to a position where it does not overlap the extension 4c. The reinforcing plate extension 6b is configured to be fixable to the front surface 5d of the backboard 5. Specifically, the reinforcing plate extension 6b has a third engagement hole 6d that is a through-hole that can be engaged with a second clip 17 that penetrates the backboard 5 to fix the reinforcing plate extension 6b to the front surface 5d of the backboard 5.

[0051] According to this configuration, the reinforcing plate extension 6b is fixed to the front surface 5d of the backboard 5 by having the above-described configuration. Specifically, the second clip 17 that penetrates the backboard 5 engages with the third engagement hole 6d of the reinforcing plate extension 6b, thereby fixing the reinforcing plate extension 6b to the front surface 5d of the backboard 5. This makes it possible to maintain the reinforcing plate 6 overlapping the backboard 5. Therefore, when the extension 4c of the rear trim 4 is fixed to the trim fixing portion 3d of the cover member 3 by the first clip 7, the reinforcing plate 6 does not shift relative to the backboard 5, improving workability.

[0052] (4) In the seat of this embodiment, the seat back 1 is provided with second clips 17 that secure the backboard 5 to the frame 2. The frame 2 has second engagement holes 2a that can engage with the second clips 17. As described above, the reinforcing plate extension 6b has third engagement holes 6d that are through-holes that can engage with the second clips 17 to secure the backboard 5 to the front surface 5d.

[0053] As shown in Figure 12, the second clip 17 penetrates the backboard 5, penetrates the third engagement hole 6d of the reinforcing plate extension 6b, and engages the reinforcing plate extension 6b with the front surface 5d of the backboard 5, and also engages with the second engagement hole 2a of the frame 2, thereby fixing the backboard 5 together with the reinforcing plate 6 to the frame 2.

[0054] According to this configuration, the second clip 17 passes through the third engagement hole 6d of the reinforcing plate extension 6b and engages the reinforcing plate extension 6b with the front surface 5d of the backboard 5. Therefore, when the first clip 7 is used to secure the extension 4c of the rear trim 4 to the trim fixing portion 3d of the cover member 3, the reinforcing plate 6 does not shift relative to the backboard 5, improving workability. Moreover, the second clip 17 is engaged with the second engagement hole 2a of the frame 2, thereby securing the backboard 5 together with the reinforcing plate 6 to the frame 2, thereby enabling the backboard 5, the reinforcing plate 6, and the extension 4c of the rear trim 4 to which the reinforcing plate 6 is fixed to be more stably fixed and improving the accuracy of the installation position.

[0055] (5) In the seat of this embodiment, as shown in Figures 2 and 6, the extension portions 4c of the rear trim 4 extend outward in the width direction Y from both side edges of the main body portion 4a in the width direction Y. The trim fixing portions 3d of the cover member 3 are provided on the inner surfaces of the pair of side portions 3b that face each other.

[0056] With this configuration, the pair of extension portions 4c of the rear trim 4 wrap around the front side X1 of the backboard 5, making it possible to stably support the backboard 5 from both sides in the width direction Y, and at the same time, the rear trim 4 and the backboard 5 can be stably fixed to the trim fixing portions 3d provided on each of the pair of side portions 3b of the cover member 3.

[0057] (6) In the seat manufacturing method of this embodiment, it is possible to continuously perform the process of combining the rear trim 4 and the backboard 5 using the extension portion 4c of the rear trim 4 and the process of simultaneously attaching the rear trim 4 and the backboard 5 to the trim fixing portion 3d of the cover member 3.

[0058] That is, when manufacturing the seat back 1, the first clip 7 is inserted through the extension 4c of the back trim 4 from the front side X1, and then the extension 4c is brought around the front side X1 of the backboard 5 together with the first clip 7, thereby combining the back trim 4 and the backboard 5. At this time, since the first clip 7 is located on the front side X1 of the backboard 5, following the process of combining the back trim 4 and the backboard 5, the combined back trim 4 and backboard 5 can be brought close to the frame 2 and the trim fixing portion 3d arranged in the space 3c of the cover member 3 from the back side X2, and the first clip 7 can be engaged with the first engagement hole 3e of the trim fixing portion 3d of the cover member 3 to fix the extension 4c to the trim fixing portion 3d. As a result, the workability of the process of fixing the backboard 5 and the back trim 4 on the back side X2 of the seat back 1 can be improved.

[0059] (Variant) (A) In the seat according to the above embodiment, the seat back 1 is provided with a second clip 17 (see Figures 2 and 12) that secures the backboard 5 to the frame 2, and is also provided with a reinforcing plate extension 6b (see Figures 6 and 12) that engages with the second clip 17. However, even without these second clips 17 and reinforcing plate extension 6b, it is possible to achieve the above (features of the embodiment) (1), (2), and (5).

[0060] For example, as a modified example of the present invention, a seat back as shown in FIG. 13 may be considered, which does not have the second clip 17 and the reinforcing plate extension 6b.

[0061] 13, this seat back does not have the second clip 17 and the reinforcing plate extension 6b, but instead has four first clips 7, four trim fixing portions 3d of the cover member 3, four through holes 4d in the extension 4c of the back trim 4, and four through holes 6c in the reinforcing plate 6 on both sides of the width direction Y of the seat back, which makes it possible to stably fix the pair of extensions 4c of the back trim 4 to the cover member 3. In the seat back of FIG. 13, since there is no second clip 17, the through holes 5a in the backboard 5 and the second engagement holes 2a in the frame 2 are also omitted.

[0062] The process for manufacturing the seat back of the modified example shown in FIG. 13 is as follows, and since there is no second clip 17, the process is further simplified.

[0063] 14, the first clip 7 is inserted from the front side X1 into the through-hole 6c of the reinforcing plate main body 6a and the through-hole 4d of the extension 4c. Then, the main body 4a of the rear trim 4 is overlapped on the backboard 5 from the rear side X2.

[0064] Next, as shown in Figures 14 to 16, the pair of extensions 4c of the rear trim 4 are wrapped around the front side X1 and folded back so as to wrap around both side edges of the backboard 5, and the pair of reinforcing plates 6 are overlapped on the front surface 5d of the backboard 5.

[0065] 17 and 18, with the pair of extensions 4c of the rear trim 4 wrapping around both side edges of the backboard 5, the first clip 7 is engaged with the first engagement hole 3e of the trim fixing portion 3d of the cover member 3. This makes it possible to simultaneously fix the rear trim 4 and the backboard 5 to the cover member 3. In this way, the seat back having the structure shown in FIG. 18 is completed.

[0066] (B) Even if the reinforcing plate 6 does not have the reinforcing plate extension 6b of the above embodiment, the backboard 5 may be fixed to the frame 2 by the second clip 17 to achieve a more stable fixation of the backboard 5. In this case, it is still possible to achieve the above features (1), (2), and (5) of the embodiment.

[0067] (C) In another modification of the present invention, instead of the second clip 17 of the above embodiment, as shown in Figures 19 and 20, the backboard 5 may be provided with a protrusion 5b that protrudes from the front surface 5d of the backboard 5 toward the forward side X1. Correspondingly, the reinforcing plate extension 6b may have a fourth engagement hole 6e with which the protrusion 5b can engage.

[0068] In this modification, the backboard 5 is made of a plastic molded product that can be molded integrally with the projections 5b.

[0069] 19 and 20, the protrusion 5b protruding from the front surface 5d of the backboard 5 toward the front side X1 engages with the fourth engagement hole 6e of the reinforcing plate extension 6b, thereby enabling the reinforcing plate extension 6b to be locked to the front surface 5d of the backboard 5. Therefore, when the extension 4c of the rear trim 4 is fixed to the trim fixing portion 3d of the cover member 3 with the first clip 7, the reinforcing plate 6 does not shift relative to the backboard 5, improving workability.

[0070] It is also possible to fix the reinforcing plate extension 6b to the backboard 5 using the opposite configuration to the modified example shown in Figures 19 and 20, i.e., by providing a protrusion on the reinforcing plate extension 6b and fitting it in an engaging hole on the backboard 5.

[0071] (D) The extension 4c of the rear trim 4 may extend not only in the width direction Y of the main body 4a as in the above embodiment and modified examples (A) to (C), but also in the vertical direction Z. Furthermore, the trim fixing portion 3d of the cover member 3 may be disposed at the end of the space 3c in the vertical direction Z, corresponding to the position of the extension 4c extending in the vertical direction Z. Even with this configuration, as in the above embodiment, the extension 4c of the rear trim 4 wraps around the front side X1 of the backboard 5, wrapping around both ends of the backboard 5 in the vertical direction Z, and overlapping the reinforcing plate 6. Then, by passing the first clip 7 through the extension 4c and the reinforcing plate 6 and engaging with the first engagement hole 3e of the trim fixing portion 3d, the extension 4c can be fixed to the trim fixing portion 3d in a state where it abuts against the abutment surface 3f of the trim fixing portion 3d of the cover member 3. This makes it possible to simultaneously fix the rear trim 4 and the backboard 5 to the cover member 3.

[0072] Summary of the embodiment The embodiment can be summarized as follows: A seat of the present embodiment is a seat having a seat back, the seat back including a frame that forms the framework of the seat back, a cover member that covers the front surface of the frame, a backboard that covers the back surface of the frame, a skin that covers the back surface of the backboard, and a first fastener that secures the skin to the cover member, the cover member including a front surface that covers the front surface of the frame, a pair of side surfaces that cover both side surfaces of the frame, and a skin fixing part that is disposed in a space formed by the front surface and the pair of side surfaces and has a first engagement hole that can engage with the first fastener, the skin has a main body that covers the back surface side of the backboard, and an extension that wraps around from a periphery of the main body to the front surface side of the backboard and is interposed between the backboard and the skin fixing part, the first fastener penetrates the extension part and is engaged with the first engagement hole of the skin fixing part, thereby securing the extension part to the skin fixing part.

[0073] According to this configuration, the skin covering the back side of the backboard has a main body that covers the back side of the backboard and an extension that wraps around from the periphery of the main body to the front side of the backboard and is interposed between the backboard and the skin fixing part, so that the extension can be used to combine the skin and the backboard, making it possible to attach the skin and backboard simultaneously.

[0074] That is, when manufacturing the seat back, the upholstery and the backboard can be combined by wrapping the extension around the front side of the backboard. Then, the extension can be fixed to the upholstery fixing portion by having the first fastener penetrate the extension and engage with the first engagement hole of the upholstery fixing portion of the cover member. This allows the upholstery and the backboard to be fixed to the upholstery fixing portion of the cover member simultaneously. As a result, it is possible to improve the workability of fixing the backboard and the upholstery on the rear side of the seat back.

[0075] In the above-described seat, the surface layer preferably has a reinforcing portion that reinforces at least the portion of the extension portion around the portion through which the first fastening device passes.

[0076] According to this configuration, the portion of the extension of the skin surrounding the portion through which the first fastener passes is reinforced by the reinforcing portion, so that the through hole of the extension is prevented from being stretched by the first fastener.

[0077] In the above-described sheet, it is preferable that the reinforcing portion is configured by the reinforcing plate fixed to the front surface of the extension portion to reinforce the extension portion.

[0078] With this configuration, the extension can be reinforced by fixing a reinforcing plate to the front surface of the extension. Furthermore, by using this reinforcing plate, the entire extension can be reinforced easily and reliably. Furthermore, the reinforcing plate ensures that the folded portion of the extension is straight, improving the appearance of the rear trim.

[0079] In the above-mentioned sheet, the reinforcing plate has a reinforcing plate main body portion that overlaps the extension portion, and a reinforcing plate extension portion that extends from the reinforcing plate main body portion to a position that does not overlap the extension portion, and it is preferable that the reinforcing plate extension portion has a configuration that can be fixed to the front surface of the backboard.

[0080] With this configuration, the reinforcing plate extension is fixed to the front surface of the backboard, so that the reinforcing plate can be kept overlapped with the backboard. Therefore, when fixing the extension of the cover to the cover fixing portion of the cover member with the first fastener, the reinforcing plate does not shift relative to the backboard, improving workability.

[0081] In the above-mentioned seat, it is preferable that the seat further includes a second fastening device for fixing the backboard to the frame, the frame having a second engagement hole that can engage with the second fastening device, the reinforcing plate extension having a third engagement hole that is a through hole that can engage with the second fastening device for fixing to the front surface of the backboard, and the second fastening device passes through the third engagement hole of the reinforcing plate extension to fasten the reinforcing plate extension to the front surface of the backboard, and is also fastened to the second engagement hole of the frame, thereby fastening the backboard together with the reinforcing plate to the frame.

[0082] According to this configuration, the second fastener passes through the third engaging hole in the reinforcing plate extension and fastens the reinforcing plate extension to the front surface of the backboard. Therefore, when fastening the extension of the upholstery to the upholstery fixing portion of the cover member with the first fastener, the reinforcing plate does not shift relative to the backboard, improving workability. Furthermore, the second fastener engages with the second engaging hole in the frame, fixing the backboard together with the reinforcing plate to the frame. This allows for more stable fixing of the backboard, reinforcing plate, and the extension of the upholstery to which the reinforcing plate is fixed, and also improves the accuracy of the installation position.

[0083] In the above seat, the backboard may have a protrusion that protrudes forward from a front surface of the backboard, and the reinforcing plate extension portion may have a fourth engagement hole with which the protrusion can engage.

[0084] With this configuration, the protrusion protruding forward from the front surface of the backboard engages with the fourth engagement hole of the reinforcing plate extension, thereby enabling the reinforcing plate extension to be locked to the front surface of the backboard. Therefore, when the extension of the cover is fixed to the cover fixing portion of the cover member with the first locking device, the reinforcing plate does not shift relative to the backboard, improving workability.

[0085] In the above-mentioned seat, it is preferable that the extension portions of the skin extend outward in the width direction from both side edges of the main body portion in the width direction, and that the skin fixing portions of the cover member are respectively provided on the opposing inner surfaces of the pair of side portions.

[0086] With this configuration, the pair of extensions of the skin wrap around to the front side of the backboard, making it possible to stably support the backboard from both sides in the width direction, and at the same time, the skin and backboard can be stably fixed to the skin fixing parts provided on each of the pair of side parts of the cover member.

[0087] The method for manufacturing a seat of this embodiment is the same as the method for manufacturing the above-mentioned seat, and is characterized by including the steps of: preparing the skin with the extension portion extended relative to the main body portion; penetrating the first fastening device from the front side of the extension portion of the skin; combining the skin and the backboard by overlapping the main body portion of the skin on the back side of the backboard and wrapping the extension portion together with the first fastening device around the front side of the backboard; and bringing the combined skin and backboard close from the back side to the frame and skin fixing portion arranged in the space of the cover member and fixing the extension portion to the skin fixing portion by engaging the first fastening device with the first engagement hole of the skin fixing portion.

[0088] With this configuration, it is possible to continuously perform the process of combining the skin and the backboard using the extension portion of the skin and the process of simultaneously attaching the skin and the backboard to the skin fixing portion of the cover member.

[0089] That is, when manufacturing the seat back, the upholstery and the backboard can be combined by passing the first fastener through the front side of the extension portion of the upholstery and then wrapping the extension portion around the front side of the backboard together with the first fastener. Since the first fastener is located on the front side of the backboard, following the process of combining the upholstery and the backboard, the combined upholstery and backboard can be brought close to the frame and the upholstery fixing portion disposed in the space of the cover member from the rear side, and the extension portion can be fixed to the upholstery fixing portion by engaging the first fastener with the first engaging hole of the upholstery fixing portion of the cover member. As a result, the workability of the process of fixing the backboard and upholstery on the rear side of the seat back can be improved.

[0090] As described above, according to the seat and the method for manufacturing the seat of this embodiment, it is possible to improve the workability in the process of fixing the backboard and the cover on the rear side of the seat back.

Claims

1. A seat having a seat back, wherein the seat back comprises: a frame that forms the skeleton of the seat back; a cover member that covers the front of the frame; a backboard that covers the back of the frame; a skin that covers the back of the backboard; and a first fastening device that secures the skin to the cover member; the cover member has a front portion that covers the front of the frame, a pair of side portions that cover both side surfaces of the frame, and a skin fixing portion that is disposed in a space formed by the front portion and the pair of side portions and has a first engaging hole that can engage with the first fastening device; the skin has a main portion that covers the back side of the backboard, and an extension portion that wraps around from the periphery of the main portion to the front side of the backboard and is interposed between the backboard and the skin fixing portion; and the first fastening device penetrates the extension portion and is engaged with the first engaging hole in the skin fixing portion, thereby securing the extension portion to the skin fixing portion.

2. A seat according to claim 1, characterized in that the skin has a reinforcing portion that reinforces at least the portion of the extension portion surrounding the portion through which the first fastening device passes.

3. A seat according to claim 2, characterized in that the reinforcing portion is constituted by the reinforcing plate which is fixed to the front surface of the extension portion to reinforce the extension portion.

4. A seat as described in claim 3, wherein the reinforcing plate has a reinforcing plate main body portion that overlaps with the extension portion, and a reinforcing plate extension portion that extends from the reinforcing plate main body portion to a position that does not overlap with the extension portion, and the reinforcing plate extension portion is configured to be able to be fixed to the front surface of the backboard.

5. A seat as described in claim 4, further comprising a second fastening device for fixing the backboard to the frame, wherein the frame has a second engagement hole that can engage with the second fastening device, and the reinforcing plate extension has a third engagement hole that is a through hole that can be engaged with the second fastening device for fixing to the front surface of the backboard, and the second fastening device passes through the third engagement hole in the reinforcing plate extension to fasten the reinforcing plate extension to the front surface of the backboard, and is also engaged with the second engagement hole in the frame, thereby fixing the backboard together with the reinforcing plate to the frame.

6. A seat as described in claim 4, wherein the backboard has a protrusion protruding forward from the front surface of the backboard, and the reinforcing plate extension has a fourth engagement hole with which the protrusion can engage.

7. A seat as claimed in any one of claims 1 to 6, wherein the extensions of the skin extend outward in the width direction from both side edges of the main body in the width direction, and the skin fixing parts of the cover member are provided on the inner surfaces of the pair of side sections that face each other.

8. A method for manufacturing a seat as described in claim 1, comprising the steps of: preparing the skin with the extension portion extended relative to the main body portion; penetrating the first fastening device from the front side of the extension portion; combining the skin and the backboard by overlapping the main body portion of the skin on the back side of the backboard and wrapping the extension portion together with the first fastening device around the front side of the backboard; and bringing the combined skin and backboard close to the frame and skin fixing portion arranged in the space of the cover member from the back side and fixing the extension portion to the skin fixing portion by engaging the first fastening device with the first engagement hole of the skin fixing portion.

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