Vehicle seat and method of manufacturing the same

Abstract

To improve shape retainability of a backside material integrated with a seat pad.SOLUTION: A vehicle seat comprises a seat pad (seating pad part 20) for elastically supporting an occupant, and a backside material 23 integrated with a back surface of the seat pad (seating pad part 20). The backside material 23 is formed of sheet-like tip urethane which has flexibility enabling bending deformation along an uneven shape of the back surface of the seat pad (seating pad part 20) and which has a mean density of 0.12 g / cm3 or more.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a vehicle seat including a seat pad and a back material integrated with the back surface of the seat pad, and a method for manufacturing the same.

Background Art

[0002] Techniques related to this type of vehicle seat are disclosed in Patent Document 1. This vehicle seat has a seat pad made of foamed resin forming its outer shape and a seat frame that supports this seat pad. And a back material is integrated with the back surface of the seat pad. This back material is formed of a surface material such as a non-woven fabric or felt having appropriate flexibility, and is bent along the back surface shape (concave-convex shape) of the seat pad. And the back material can be integrated, for example, simultaneously with the molding of the seat pad. That is, the back material is pre-set in the cavity of the mold with a separate member such as a magnet. Subsequently, by molding the seat pad in the cavity, the back material can be integrated with the back surface of this seat pad. In the above-described configuration, due to the function of the back material, the seat pad is reinforced, and the seat pad and the seat frame do not directly contact each other.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in the field of vehicle seats, a back material spread out in a planar shape is integrated with a seat pad. However, since known back materials are made of fiber materials such as non-woven fabrics and felts, they are prone to losing their shape and lack somewhat in shape retention. For this reason, during integral molding or the like, it has been necessary to set while taking care that the back material does not curl or loosen, and even if sufficient care is taken, there has been a risk that the back material may be partially moved by the molding pressure (external force). And in such a case, the back material is integrated with the seat pad in a state where wrinkles and looseness have occurred. Although it is conceivable to increase the number of magnets for setting, if this is done, a large number of magnets, that is, unnecessary separate members remain in the vehicle seat after molding. Furthermore, in the above-described configuration, if the back material is too light with respect to the seat pad, there is a risk of generating abnormal noise due to stick-slip. The present invention was devised in view of the above points, and the problem to be solved by the present invention is to further improve the shape retention of the back material integrated with the seat pad.

Means for Solving the Problem

[0005] As a means for solving the above problem, in the vehicle seat of the first invention, it includes a seat pad that elastically supports an occupant, and a back material integrated with the back surface of the seat pad, and the back material has flexibility that can be bent along the uneven shape of the back surface of the seat pad. In this type of configuration, it is desirable that the shape retention of the back material integrated with the seat pad can be further improved. Therefore, the back material of the present invention is formed of sheet-shaped chip urethane having an average density of 0.12 g / cm 3 or more. The back material of the present invention is formed by solidifying chip urethane into a sheet shape so as to have appropriate flexibility. And by forming the back material with a sheet material of chip urethane having a predetermined density and having an appropriate weight, the shape retention of this back material is improved. As a result, the back material can be integrated with the back surface of the seat pad in a more appropriate form.

[0006] The vehicle seat of the second invention is the vehicle seat of the first invention, wherein the back material has an average thickness dimension set to 25 mm or less. In the present invention, by suppressing the thickness dimension of the back material to a predetermined value so that it does not become excessively large, it becomes easier to secure the thickness dimension of the seat pad that supports the occupant.

[0007] The vehicle seat of the third invention is the vehicle seat of the second invention, wherein the back material has a constant thickness dimension throughout its surface direction. In the present invention, by making the thickness dimension of the back material constant, it becomes easier to secure the thickness dimension of the seat pad that supports the occupant at any location.

[0008] The vehicle seat of the fourth invention is the vehicle seat of any one of the first to third inventions, wherein the seat pad is formed of molded urethane. In the present invention, the seat pad and the back material can be formed of the same material, resulting in a configuration that contributes to ensuring recyclability.

[0009] The manufacturing method of the vehicle seat of the fifth invention is the manufacturing method of the vehicle seat described in the first invention. After setting the back material in the cavity of the molding die, the seat pad is molded in the cavity. And at that time, the area of the back material is made smaller than the area of the back surface of the seat pad, and the back material is set in the molding die so as to be disposed inside the outer peripheral edge of the seat pad. In the present invention, the molding die can be closed to form the cavity without being obstructed by the back material as much as possible.

[0010] The manufacturing method of the vehicle seat of the sixth invention is the manufacturing method of the vehicle seat of the fifth invention. An insertion convex portion fixed in the cavity is inserted through a through portion provided on the outer peripheral edge side of the back material, and the back material is set in the cavity. In the present invention, the back material can be set in the cavity without requiring a separate member such as a magnet.

Advantages of the Invention

[0011] According to the first invention of the present invention, the shape retention of the back material integrated with the seat pad can be further improved. According to the second invention, the back material can be integrated with the seat pad in a more appropriate state. According to the third invention, the back material can be integrated with the seat pad in an even more appropriate state. According to the fourth invention, the seat pad and the back material can be integrated while ensuring recyclability. According to the fifth invention, a back material with excellent shape retention can be more appropriately integrated with the seat pad. And according to the sixth invention, the back material can be even more appropriately integrated with the seat pad.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Modes for Carrying Out the Invention

[0013] Hereinafter, embodiments for carrying out the present invention will be described with reference to FIGS. 1 to 8. In each figure, arrows indicating the front-rear direction, the vertical direction, and the left-right direction (seat width direction) of the vehicle seat are appropriately shown. In each figure, for the sake of convenience, the seat cover (and its related members) is illustrated by a dashed line, or the illustration of the seat cover is omitted. Also, in FIGS. 2, 4, 7, and 8, for the sake of convenience, the support pad portion is hatched to distinguish it from the back material (and the seating pad portion). And in FIG. 2, for the sake of convenience, the seating pad portion and the back material are illustrated without hatching, but in FIG. 5, the seating pad portion and the back material are illustrated with different hatches.

[0014] [Overview of Vehicle Seat] First, the overview of the vehicle seat 2 shown in FIG. 1 will be described. In this vehicle seat 2, the lower part of the seat back 6 is connected to the rear part of the seat cushion 4 serving as the seat part via a recliner (not shown). Also, a headrest 8 is provided on the upper part of the seat back 6. Here, the seat cushion 4 is formed in a rectangle that is long in the front-rear direction in a top view, and a seating part 10 where an occupant can sit is provided in the center of the seat width direction so as to extend in the seat front-rear direction. Also, on both sides (left and right) in the seat width direction of the seating part 10, a right-side armrest 11 and a left-side armrest 12 that support the side parts of the occupant are provided so as to bulge upward on the seating side, that is, the upper side of the seat. And the right-side armrest 11 and the left-side armrest 12 have substantially the same configuration and are formed to be symmetric about the left and right.

[0015] And as shown in FIG. 2, the seat cushion 4 has a plurality of pad portions (seating pad portion 20, pad portion 21, support pad portion 22) that elastically support the occupant (in FIG. 2, for the sake of convenience, reference numerals corresponding to the respective components of the right embankment portion 11 are attached, and reference numerals corresponding to the respective components of the left embankment portion 12 are attached in parentheses). Further, the outer surface (appearance) of the seat cushion 4 is formed by a seat cover 4S provided so as to cover each pad. And the seating pad portion 20 is a portion that forms the outer shape of the seating portion 10, and is provided so as to extend in the front-rear direction at the center of the seat cushion 4 (see FIG. 3). This seating pad portion 20 can be formed of a foamed resin having an appropriate softness, for example, an average density of 0.3 g / cm 3 ~0.7 g / cm 3 . As this type of foamed resin, various foamed resins can be exemplified. For example, it is preferably polyurethane foam. In this embodiment, polyurethane foam (molded urethane) obtained by mold molding is used.

[0016] Also, the right embankment portion 11 and the left embankment portion 12 shown in FIG. 2 have a pad portion 21 disposed on the seating side and a support pad portion 22 that supports the pad portion 21 from the back side (lower side). And the pad portion 21 is moderately soft from the viewpoint of ensuring riding comfort, and the support pad portion 22 is moderately hard from the viewpoint of ensuring supportability. And referring to FIGS. 2 and 3, the pad portion 21 can be formed separately from the seating pad portion 20, but in this embodiment, it is formed as an integrally molded product with the seating pad portion 20. A groove portion 7 for drawing in the seat cover 4S is formed between the seating pad portion 20 and the pad portion 21.

[0017] Also, the support pad portion 22 of the right embankment portion 11 shown in FIG. 2 is formed such that the portion on the inner side (left side) in the sheet width direction protrudes beyond the left portion of the seating pad portion 20. Also, the support pad portion (22) of the left embankment portion 12 is formed such that the portion on the inner side (right side) in the sheet width direction protrudes beyond the right portion of the seating pad portion 20. And a back material 23 is integrated with the back surface of the seating pad portion 20, and this back material 23 is disposed between the right embankment portion 11 and the left embankment portion 12 (between the left and right support pad portions 22) as shown in FIGS. 2 and 4. Further, as shown in FIG. 5, the back surface of the seating pad portion 20 has an uneven shape, and the back material 23 is bent and integrated along this back surface shape. And the seating pad portion 20 and the back material 23 are supported by various frames (front frame 31, rear frame 32, intermediate frame 33, etc.) of the seat cushion 4 as shown in FIG. 5.

[0018] In the vehicle seat 2 shown in FIG. 5, as described above, the back material 23 is bent and integrated along the back surface of the seating pad portion 20 (seat pad). In this type of configuration, it is desirable to integrate the back material 23 with the seating pad portion 20 in a more appropriate form. For this reason, during the integral molding described later, the back material 23 is integrated with the seating pad portion 20 in as appropriate a form as possible, but the use of separate members such as magnets should be avoided as much as possible. Therefore, in this embodiment, as will be described later, the shape retention of the back material 23 integrated with the seat pad is to be further improved. Hereinafter, the configuration of the vehicle seat 2 will be described in detail in the order of various frames (31 to 33), the seating pad portion 20, the back material 23, and the integral molding method.

[0019] [Frame] First, the seating pad portion 20 shown in FIG. 5 is supported by various frames as described above. Here, in the seat cushion 4, a front frame 31 at the front position, a rear frame 32 at the rear position, and an intermediate frame 33 at the front-rear center position are arranged so as to extend in the seat width direction. Further, a support member 34 is passed between the intermediate frame 33 and the rear frame 32 and locked. The support member 34 extends in the front-rear direction of the seat and is formed in a substantially trapezoidal shape in side view, so that the middle part thereof in the front-rear direction of the seat is bent so as to protrude downward from the seat. The support member 34 can be formed of a plurality of wire materials bent in a zigzag shape in the seat width direction and extending in the front-rear direction of the seat, or a surface material such as a cloth stretched within a frame.

[0020] [Seating pad portion (seat pad)] Next, the seating pad portion 20 shown in FIG. 5 corresponds to the seat pad of the present invention, and its back surface shape is an uneven shape so that the above-described respective frames can be arranged. That is, on the back surface of the seating pad portion 20, a front recess 41 provided on the front end portion 201 side and a rear recess 42 provided on the rear end portion 202 side are formed so as to be recessed upward from the seat. Further, the front part side of the back surface of the seating pad portion 20 is slightly concave so that the intermediate frame 33 can be arranged. And on the rear part side of the back surface of the seating pad portion 20, a convex portion 43 where the support member 34 is arranged is formed so as to protrude downward from the seat.

[0021] [Back surface material] Next, the back surface material 23 shown in FIG. 5 is formed in a sheet shape having flexibility that can be bent and deformed. Further, the back surface material 23 is arranged in a portion from the front recess 41 to the rear recess 42 of the seating pad portion 20, and is bent and arranged along the uneven shape (front recess 41, convex portion 43, rear recess 42). And the back surface material 23 is formed of the above-mentioned chip urethane, and desirably has an average density of 1.5 times or more, preferably 2 times or more, that of the above-described seating pad portion 20. The upper limit value of the average density of the back surface material 23 (chip urethane) is not particularly limited as long as it can be formed. For example, the average density is 0.4 g / cm 3 The above chip urethane has an average density that is 1.5 times or more, preferably 2 times or more, that of the seating pad portion 20. Also, the upper limit value of the average density of the back surface material 23 (chip urethane) is not particularly limited as long as it can be molded. For example, the average density is 0.4 g / cm 3By doing the following, it will have the desired flexibility. Note that when using chip urethane with an average density exceeding 0.4 g / cm 3 it is desirable to make it uneven in advance by a method such as compression molding when using chip urethane exceeding 3 , and it can be regarded as having flexibility as much as possible as long as it can be made uneven. And the average density (average value of apparent density) of the back material 23 and the seating pad portion 20 can be measured in accordance with "JIS K 7222:2005".

[0022] Here, the chip urethane is formed by solidifying crushed polyurethane foam into a sheet with the addition of an adhesive, and it can be molded to a relatively high density (for example, up to an average density of 0.5 g / cm 3 to some extent) by a method such as compression molding. And the chip urethane with the above-mentioned average density is superior in shape retention to typical non-woven fabrics and felts, and because it is moderately heavy, it is difficult to be deformed by an external force. Here, the crushed polyurethane foam can be obtained from mold urethane, slab urethane, etc. And as the crushed material, used urethane foam can also be used, and in this case, even if there is a variation in density for each lot, it is possible to adjust the density by compression molding.

[0023] [Thickness dimension of the back material] Also, the thickness dimension S1 of the back material 23 shown in FIG. 5 is not particularly limited, but it is desirable to make it as small (thin) as possible from the viewpoint of ensuring the performance of the seating pad portion 20. For example, in the back material 23, its average thickness dimension can be set in the range of 1 to 25 mm, more preferably in the range of 3 to 15 mm, and still more preferably in the range of 4 to 10 mm. And although the back material 23 may be provided with a slight difference in thickness partially, it is desirable to make the thickness dimension constant throughout its surface direction (the sheet front-rear direction and the sheet width direction). Here, the thickness dimension being constant means that in addition to the case where the thickness dimension of the entire area of the back material 23 is the same, variations in thickness due to design errors in the manufacturing type of chip urethane, etc. are allowed. For example, even when the difference between the thickest part and the thinnest part of the back material 23 is 1 mm or less, it can be regarded as constant. The average thickness dimension can be measured, for example, by collecting 10 square samples of 1×1 cm (when there is a difference in thickness, 10 samples including the thickest part and the thinnest part) and calculating their average value.

[0024] [Method for manufacturing a vehicle seat (integration of the seating pad portion and the back material)] In the vehicle seat 2 shown in FIG. 1, it is desirable to integrate the back material 23 with the seating pad portion 20 in a more appropriate form by integral molding or the like described later. Therefore, the back material 23 shown in FIG. 5 has an average density of 0.12 g / cm 3 It is formed of the above sheet-like chip urethane. This back material 23 is formed by solidifying the chip urethane into a sheet shape so as to have appropriate flexibility. And by forming the back material 23 with a sheet material of chip urethane having a predetermined density and an appropriate weight, the shape retention of this back material 23 is improved. As a result, the back material 23 can be integrated with the seating pad portion 20 in a more appropriate form. Therefore, the advantages of the back material 23 will be described in detail below together with the procedure of integral molding with the seating pad portion 20.

[0025] [Molding die] First, the seating pad portion 20 shown in FIG. 6 is molded within the cavity 53 of the mold 50, that is, within the cavity 53 formed between the first mold 51 and the second mold 52 (in FIG. 6, the back material during the molding of the seating pad portion is shown, but for the sake of convenience, the illustration of the seating pad portion during the molding process is omitted). On this first mold 51, a front-side molding portion 54 that follows the shape of the seating surface of the seating pad portion 20 is formed, and the outer peripheral edge side outside this front-side molding portion 54 is the first mold closing surface 510. Also, on the second mold 52, a back-side molding portion 55 that follows the shape of the back surface of the seating pad portion 20 is formed, and the outer peripheral edge side outside this back-side molding portion 55 is the second mold closing surface 520. And on the back-side molding portion 55 of the second mold 52, at appropriate positions, the first insertion convex portion 61 and the second insertion convex portion 62 are fixed in a shaft-like (cylindrical) shape protruding into the cavity 53. For example, referring to FIGS. 5 and 6, the first insertion convex portion 61 is fixed at a position behind the portion that molds the front-back side of the seating pad portion 20, that is, behind the first convex portion 410 that molds the front recess 41. Also, the second insertion convex portion 62 is fixed at the rear part of the portion that molds the rear-back side of the seating pad portion 20, that is, at the rear part of the second convex portion 420 that molds the rear recess 42.

[0026] [Set of back material] Prior to molding the seating pad portion 20, the back material 23 is set on the back molding portion 55 of the second mold 52 shown in FIG. 6. Here, as shown in FIG. 7, a first through portion 71 (through hole) is formed in the back material 23 at a position where the first insertion convex portion 61 can be inserted, and this first through portion 71 is arranged at a position closer to the left side of the front part of the seat. Further, a second through portion 72 (through hole) is formed in the back material 23 at a position where the second insertion convex portion 62 can be inserted, and this second through portion 72 is arranged at a position closer to the right side of the rear part of the seat. Also, with reference to FIGS. 5 and 6, the back material 23 is set so that its area is smaller than the area of the back surface of the seating pad portion 20, that is, the surface area of the back molding portion 55. Then, as shown in FIG. 6, the back material 23 is inserted into the first through portion 71 with the first insertion convex portion 61 and into the second through portion 72 with the second insertion convex portion 62, and is set at a position inside the outer edge portion (second mold closing surface 520) of the back molding portion 55. The back material 23 thus set comes to be arranged in the portion from the first convex portion 410 to the second convex portion 420 of the back molding portion 55. According to the above-described configuration, the back material 23 can be set in place on the back molding portion 55 without requiring a separate member such as a magnet. Further, since the back material 23 is formed of a chip urethane sheet material having a predetermined density and has excellent shape retention, it is difficult to collapse even when an external force is applied. For this reason, the back material 23 can be set in the back molding portion 55 without being curled or loosened as much as possible, and excessive care during setting is not required. Also, since the back material 23 has appropriate flexibility, it can be arranged along the back molding portion 55 while bending an appropriate portion thereof.

[0027] [Molding of the seating pad portion] Next, referring to FIG. 6, the molding material is foamed and cured within the cavity 53 between the closed first mold 51 and the second mold 52. At this time, since the back material 23 is disposed on the inner side of the second mold closing surface 520 as described above, it becomes difficult for the back material 23 to be sandwiched between the first mold closing surface 510 and the second mold closing surface 520. Then, the seating pad portion 20 is integrated with the back material 23 while being molded within the cavity 53. At this time, since the back material 23 has an appropriate weight, it is difficult to move even by the molding pressure during molding. By suppressing the movement of the back material 23 in this way, it is possible to avoid as much as possible a situation where the gas during molding flows into the end side of the back material 23 and a gas pocket is generated. As a result, while suppressing the collapse of the back material 23, it is possible to further avoid as much as possible an unintended missing portion in the seating pad portion 20. Then, when the molding material is cured and the seating pad portion 20 is formed, the back material 23 is integrated at an appropriate position of the seating pad portion 20, that is, in the portion from the front recess 41 to the rear recess 42.

[0028] Then, the seating pad portion 20 and the back material 23 are taken out from the mold 50 shown in FIG. 6. At this time, the first insertion convex portion 61 and the second insertion convex portion 62 extracted from the back material 23 remain in the second mold 52 as they are. As a result, no unnecessary separate members remain in the seating pad portion 20 and the back material 23 after molding. And as shown in FIG. 5, since the front end portion 201 of the seating pad portion 20 is disposed on the front side of the back material 23 and the rear end portion 202 of the seating pad portion 20 is disposed on the rear side of the back material 23, it becomes difficult for the back material 23 to be excessively exposed to the outside.

[0029] [Modification Example] Here, the configurations of the molding die and the back material can take various configurations in addition to the above-described configurations. For example, at the front portion of the back material 23 of the modified example shown in FIG. 8, a left penetrating portion 73 on the left side of the sheet and a right penetrating portion 74 on the right side of the sheet are formed at appropriate intervals left and right. Further, in the back molding portion of the second die, a left insertion convex portion 63 inserted into the left penetrating portion 73 and a right insertion convex portion 64 inserted into the right penetrating portion 74 are formed. In the above-described configuration, with the second die disposed on the lower side, the left insertion convex portion 63 is inserted into the left penetrating portion 73, and the right insertion convex portion 64 is inserted into the right penetrating portion 74. Then, the rear portion of the back material 23 moves downward due to its own weight and fits into the second die, so that the back material 23 is set at the appropriate position of the back molding portion 55.

[0030] [Function of the back material in the seat cushion] In the seat cushion 4 shown in FIG. 5, due to the function of the back material 23, the seating pad portion 20 is reinforced and the seating pad portion 20 does not directly contact various frames. Thereby, it is possible to avoid the unintentional breakage and generation of abnormal noise of the seating pad portion 20 as much as possible. And in the seat cushion 4, the back material 23 is formed of chip urethane having a desired average density and has an appropriate weight. Therefore, according to the above-described configuration, it is possible to avoid a situation where the back material 23 becomes excessively light with respect to the seating pad portion 20, and it is possible to suppress the generation of abnormal noise due to stick-slip. Further, since the back material 23 made of chip urethane has lower friction than a fiber material, it is difficult to relatively move with respect to various frames, so that the generation of abnormal noise caused by these can be more surely suppressed. Also, high-density chip urethane has excellent airtightness (0 cc / cm 2 ·sec to 10 cc / cm 2 ·sec level) by being hardened with an adhesive. Therefore, when applied to a vehicle seat (not shown) having an air conditioning function, it is possible to suppress unintentional air leakage from the back material 23.

[0031] Also, the back material 23 shown in FIG. 5 has its thickness dimension S1 minimized (made thin) as much as possible. For this reason, the thickness dimension S2 of the seating pad portion 20 can be appropriately ensured, resulting in a configuration that contributes to ensuring excellent riding comfort. At this time, by making the thickness dimension constant in the surface direction of the back material 23, it becomes easier to ensure the thickness dimension S2 of the seating pad portion 20 that supports the occupant at any location in its back direction. Also, it becomes difficult for the occupant to feel the hardness of the back material 23 through the seating pad portion 20, and the occurrence of unintended discomfort can be suppressed as much as possible. And in the seat cushion 4, from the perspective of single materialization, the seating pad portion 20 and the back material 23 are formed of the same material, and by further adopting chip urethane as a recycled product, it becomes a configuration that contributes to ensuring recyclability.

[0032] As described above, the back material 23 of the present embodiment is formed by solidifying chip urethane into a sheet shape so as to have appropriate flexibility. And by forming the back material 23 with a sheet material of chip urethane having a predetermined density and an appropriate weight, the shape retention of this back material 23 is improved. For this reason, according to the present embodiment, the shape retention of the back material 23 integrated with the seating pad portion 20 can be further improved. And it becomes possible to integrate the back material 23 with the back surface of the seating pad portion 20 (seat pad) in a more appropriate form.

[0033] Also, in the present embodiment, by suppressing the thickness dimension of the back material 23 to a predetermined value so that it does not become excessively large, it becomes easier to ensure the thickness dimension of the seating pad portion 20 that supports the occupant. Also, in the present embodiment, by making the thickness dimension of the back material 23 constant, it becomes easier to ensure the thickness dimension of the seating pad portion 20 that supports the occupant at any location. Also, in the present embodiment, the seating pad portion 20 and the back material 23 can be formed of the same material, resulting in a configuration that contributes to ensuring recyclability. Further, in the present embodiment, the mold can be closed to form the cavity 53 without being obstructed by the back material 23 as much as possible. And in the present embodiment, the back material 23 can be set in the cavity 53 without requiring a separate member such as a magnet.

[0034] The vehicle seat of the present embodiment is not limited to the above-described embodiment, and various other embodiments can be adopted. For example, the seating pad portion and the back material may be integrally molded, or may be formed separately and then integrated with an adhesive. For example, a back material that has been pre-concave-convexed can be adhered to the seating pad portion, and in this case as well, the work is facilitated by using a back material with excellent shape retention. Also, the back material may be integrated with substantially the entire back surface of the seating pad portion. In this case, a part of the support pad portion shown in FIG. 2 does not protrude toward the seating pad portion side. Note that the back material and the support pad portion can be integrally molded. And in the seat cushion, the configuration of each pad portion, frame, and seat cover can be appropriately changed, and it is sufficient to have at least a seat pad (a portion corresponding to the seating pad portion) that can support an occupant and a back material. And the back surface shape (concave-convex shape) of the seat pad can be set according to the configuration of various members (frame or other members) arranged on the back side thereof, and it is also possible to set it independently of the various members.

[0035] Also, the method of integrally molding the seating pad portion and the back material can be appropriately changed. For example, the insertion convex portion can be formed at an appropriate position of the mold, and it may be singular or a plurality of three or more. And the back material has various through portions through which the insertion convex portion can be inserted, and these through portions may be formed not only as through holes but also as slits or the like. Also, the through portion can be formed as a thin portion, and the insertion convex portion can be inserted by piercing through this through portion. Also, the formation position of the through portion (insertion convex portion) can be appropriately changed. For example, in addition to the front portion and the rear portion of the back material, the through portion can be formed at any position. Note that the area of the back material is not particularly limited as long as it can be integrated with the seat pad, and in the case of integral molding, it is not particularly limited as long as the mold can be closed. And the configuration of the present embodiment can be applied not only to the seat cushion but also to the seat back and headrest, and can be applied to vehicle seats in general such as vehicles, airplanes, trains, and ships.

Explanation of Reference Numerals

[0036] 2 Vehicle seat 4 Seat cushion 6 Seat back 8 Headrest 4S Seat Cover 10 Seating Portion 11 Right Side Embankment 12 Left Side Embankment 20 Seating Pad Portion 201 Front End Portion (of the seating pad portion) 202 Rear End Portion (of the seating pad portion) 21 Pad Portion 22 Support Pad Portion 23 Backing Material 31 Front Frame 32 Rear Frame 33 Intermediate Frame 34 Support Member 41 Front Concave Portion 42 Rear Concave Portion 43 Convex Portion 50 Molding Die 51 First Die 52 Second Die 53 Cavity 54 Front Side Molding Portion 55 Back Side Molding Portion 61 First Insertion Convex Portion 62 Second Insertion Convex Portion 71 First Through Portion 72 Second Through Portion 410 First Convex Portion 420 Second Convex Portion 510 First Die Closing Surface 520 Second Die Closing Surface 63 Left Side Insertion Convex Portion (of the modified example) 64 Right Side Insertion Convex Portion (of the modified example) 73 Left Side Through Portion (of the modified example) 74 Right Side Through Portion (of the modified example)

Claims

1. In a vehicle seat comprising a seat pad that elastically supports an occupant and a back surface material integrated with the back surface of the seat pad, the back surface material has flexibility to be bend-deformed along the uneven shape of the back surface of the seat pad, and is formed of sheet-like chip urethane having an average density of 0.12 g / cm 3 or more. The vehicle seat.

2. The vehicle seat according to claim 1, wherein the back surface material has an average thickness dimension set to 25 mm or less.

3. The vehicle seat according to claim 2, wherein the back surface material has a constant thickness dimension throughout the surface direction.

4. The vehicle seat according to any one of claims 1 to 3, wherein the seat pad is formed of molded urethane.

5. In the method for manufacturing a vehicle seat according to claim 1, after setting the back surface material in the cavity of a mold, when molding the seat pad in the cavity, the area of the back surface material is made smaller than the area of the back surface of the seat pad, and the back surface material is set in the mold so as to be disposed inside the outer peripheral edge of the seat pad. The method for manufacturing a vehicle seat.

6. The method for manufacturing a vehicle seat according to claim 5, wherein an insertion convex portion fixed in the cavity is inserted through a through portion provided on the outer peripheral edge side of the back surface material to set the back surface material in the cavity.

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