Ventilation mat and seat

Abstract

To provide a ventilation mat having a structure for inhibiting reduction of the air quantity of air from an air blowing source and a reduced number of components compared to conventional ventilation mats, and to provide a seat in which the ventilation mat is incorporated.SOLUTION: A ventilation mat 1 has: a base material 12 including a three dimensional structure having air permeability; and a first cover material 11 disposed on one surface of the base material 12. The first cover material 11 is slightly larger than the base material 12 and has peripheral edge parts 50 extending from the base material 12. The ventilation mat 1 has a second cover material 21 which is disposed on a surface on which the first cover material is not disposed of the base material 12. In the ventilation mat 1, the peripheral edge parts 50 have adhesiveness, and the base material 12 and one or both of the first cover material 11 and the second cover material 21 are engaged by engaging members 30.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a seat installed in, for example, an automobile or the like, and a ventilation mat used therewith, and in particular to a configuration suitable for blowing air through the seat. [Background technology]

[0002] For example, when sitting in a car seat for a long period of time, especially under conditions of high ambient temperature and humidity, the surface of the seat and the human body can become "stuffy" or "sticky." This "stuffiness" or "stickiness" can impair the comfort of the seated person, and various countermeasures to this problem have been studied.

[0003] As one example of such a study, the applicant has proposed patent documents 1 to 3. Patent documents 1 to 3 show schematic cross-sectional views of a seat incorporating a ventilation mat as an air blower. The ventilation mat is composed of a ventilation mat body and a ventilation guide. The ventilation mat body comprises a base material with a breathable three-dimensional structure and a side barrier made of a non-breathable material covering the base material. The ventilation guide comprises a base material with a breathable three-dimensional structure and a tube made of a non-breathable material covering the base material. Air blown from an air source such as a fan passes through the ventilation guide and the base material of the ventilation mat body and is blown out from a breathable cover covering one side of the base material of the ventilation mat body, thereby blowing air to the seated person. This air blowing eliminates the "stuffiness" and "stickiness" of the seated person. Related technologies include, for example, patent documents 4 to 9. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication WO2018 / 221422: Kurabe [Patent Document 2] Patent Publication No. 2020-32924: Kurabe [Patent Document 3] Patent Publication No. 2023-112769: Kurabe [Patent Document 4] JP 2007-84039 A: Bridgestone [Patent Document 5] JP 2017-71368 Publication: Bridgestone [Patent Document 6] Patent No. 4107033: Matsushita Electric Industrial Co., Ltd. [Patent Document 7] Patent No. 4125721: WET [Patent Document 8] Patent No. 4999455: Kurabe [Patent Document 9] Patent No. 5430085: Kurabe DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0005] Generally, ventilation mats are required to have a structure that minimizes attenuation of the airflow from the air source and to have a simple configuration. As the number of components increases, the cost of parts increases, and if the configuration is complex, the assembly cost also rises.

[0006] The present invention was made to solve these problems of the conventional technology, and its purpose is to provide a structure that suppresses the attenuation of the air volume from the air source and reduces the number of constituent parts compared to conventional ventilation mats. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, the ventilation mat of the present invention has a base material with a breathable three-dimensional structure and a first cover material arranged on one side of the base material, wherein the first cover material is one size larger than the base material and has a peripheral portion extending from the base material. It is also conceivable that the substrate has a second cover material disposed on the side thereof on which the first cover material is not disposed. It is also considered that the peripheral edge portion has adhesive properties. It is also conceivable that the substrate and either or both of the first cover material and the second cover material are engaged with each other by an engaging member. It is also conceivable that the location engaged by the engaging member is near the outer periphery of the base material. It is also conceivable that the portion engaged by the engaging member is approximately the center of the base material. It is also conceivable that the engaging member is a sewing thread. It is also conceivable that the first cover material has an opening formed therein. It is also conceivable that the peripheral edge of the first cover material extending beyond the base material has a notch formed from the outer periphery toward the center. The seat according to the present invention comprises a seat cushion material, a leather cover, and the ventilation mat, wherein the seat cushion material and the ventilation mat are covered with the leather cover, a recess is formed in the seat cushion material, and the ventilation mat is arranged in the recess of the seat cushion material. In addition, the seat according to the present invention comprises a seat cushion material, a skin cover, and the ventilation mat, wherein the seat cushion material is covered with the skin cover, a through hole is formed in the seat cushion material, and the ventilation mat is connected to the through hole in the seat cushion material. [Effects of the Invention]

[0008] The ventilation mat of the present invention includes a first cover material that is slightly larger than the base material and has a peripheral edge. The peripheral edge of the first cover material serves as a lid for the ventilation flow path, preventing air leakage from the ventilation flow path whether the mat is installed on the upper or lower surface of the seat. This reduces attenuation of the air volume reaching the user from the air source, while still achieving a simple configuration. Furthermore, by engaging the components at predetermined positions, the components can be securely fixed, effectively suppressing noise caused by friction between the components. [Brief explanation of the drawings]

[0009] [Figure 1] 1A and 1B are an exploded perspective view and a perspective view of a first embodiment of a ventilation mat of the present invention. [Figure 2] 10A and 10B are an exploded perspective view and a perspective view of a second embodiment of the ventilation mat of the present invention. [Figure 3] 7 is a schematic cross-sectional view of a seat equipped with the ventilation mat of the first and second embodiments of the present invention, and is a cross-sectional view taken along line IV-IV' in FIG. 6. FIG. [Figure 4] 10A and 10B are an exploded perspective view and a perspective view of a third embodiment of the ventilation mat of the present invention. [Figure 5] 7 is a schematic cross-sectional view of a seat equipped with a ventilation mat according to a third embodiment of the present invention, taken along line IV-IV' in FIG. 6. FIG. [Figure 6] 1 is a schematic diagram of a seat equipped with a ventilation mat of the present invention. [Figure 7] FIG. 1 is a perspective view of a ventilation mat according to another embodiment of the present invention, different from the first to third embodiments. BEST MODE FOR CARRYING OUT THE INVENTION

[0010] Preferred embodiments of the present invention will now be described with reference to the drawings.

[0011] In the following description, the surfaces of the seat 60, backrest 61, seat surface 62 and cushion material 64 that come into contact with the buttocks or back of the seated person will be referred to as the front surface, and the surfaces that do not come into contact with the buttocks or back of the seated person will be referred to as the back surface.

[0012] (First embodiment) A first embodiment will be described below with reference to Figures 1 and 3. The ventilation mat 1 described below is provided on at least one of the seat surface 62 and the backrest 64 of a seat 60. The ventilation mat 1 according to the first embodiment is actually installed on the rear surface of the cushion material 64, and is therefore mounted on the seat surface 62 in a manner that is not visible to the seated occupant. A fan 40 is connected to the ventilation mat 1 as an air source, and air is sucked from or blown into the ventilation mat 1 by this fan 40.

[0013] Fig. 1 shows a perspective view of a ventilation mat 1 according to a first embodiment, and Figs. 2 and 4 show perspective views of ventilation mats 1 according to second and third embodiments, respectively.

[0014] As shown in FIG. 1, the ventilation mat 1 according to the first embodiment has a base material 12 with a three-dimensional structure and a first cover material 11 that is slightly larger than the base material 12. Such a ventilation mat 1 is placed on a cushion material 64 of a seat as shown in FIG. 3. A ventilation guide 22 is connected to the base material 12 of this ventilation mat 1. This ventilation guide 22 may be replaced with a through-hole (not shown). A fan 40 is connected to either the ventilation guide 22 or the through-hole via the base material 12, and ventilation is performed through the ventilation mat 1. The through-holes can be created using any known method, such as forming the cushion material 64 using a predetermined mold or drilling the cushion material 64.

[0015] The ventilation mat 1 may include, for example, a base material 12 and a first cover material 11. An opening 15d may be formed in the first cover 11. The opening 15d shown in FIG. 1 is an opening provided on the side farther from the user. The opening 15d is provided for connecting a fan 40 to the base material 12, etc.

[0016] The substrate 12 in the first embodiment functions as a spacer and an air flow path and is a sheet with a breathable three-dimensional structure. The substrate 12 is, for example, a 3D mesh sheet made of three-dimensionally woven fibers. When cutting this 3D mesh sheet into a predetermined shape, it is preferable to process it by laser cutting. This can prevent the generation of fiber waste due to fraying at the edge.

[0017] The first cover material 11 is a flat member such as a nonwoven fabric, and is preferably made of a material that is unlikely to make noise when in contact with the base material 12 and that has excellent breathability. The first cover material 11 is preferably one size larger than the base material 12, and specifically, is preferably 120% or more larger than the base material 12 in terms of area ratio.

[0018] The first cover material 11 has a peripheral edge 50 that extends slightly larger than the base material 12, and the peripheral edge 50 preferably has adhesive properties. The adhesive may be a double-sided adhesive tape, adhesive, or hook-and-loop fastener, but double-sided adhesive tape is preferred from the viewpoint of processability. Furthermore, since this adhesive is used to secure the mat to the cushion material 64, it is preferable that the adhesive properties with the cushion material 64 be considered. This adhesive preferably secures the ventilation mat 1 to the cushion material 64 of the seat 60 at the peripheral edge 50, as shown in FIG. 3. This configuration allows the peripheral edge 50 to function as a lid for the ventilation flow path (i.e., the base material 12), preventing air leakage from the ventilation flow path whether the mat is installed on the front or back surface of the seat 60.

[0019] The base material 12 and the first cover material 11 are preferably engaged with each other by an engaging member 30. The engaging member 30 may be various members such as sewing thread, bannock pins, stapler needles, adhesives, etc., but from the viewpoint of fastening strength and seating comfort, engagement by sewing thread is preferred. The engaged parts are preferably near the outer periphery of each member, as shown in FIG. 1. Engaging near the outer periphery secures the parts that are particularly subject to pressure when the human body sits, suppressing friction between the components and preventing the generation of abnormal noise. Engaging near the outer periphery also suppresses curling of the component ends during the manufacturing process, improving manufacturing efficiency.

[0020] In the present invention, the outer periphery of the substrate 12 is defined as 20 percent of the width of the substrate 12 from the edge. With regard to the outer periphery of the first cover material 11, the portion that overlaps with the outer periphery of the substrate 12 is defined as the outer periphery of the cover material. Furthermore, the portion of each member that is not the outer periphery is defined as the center.

[0021] In addition, it is also preferable to engage the respective components at their approximate centers, as shown in Figures 1 and 7. By engaging the respective components at their approximate centers, the components are more firmly fixed together than in a configuration in which only the peripheral areas are engaged, which can better suppress friction between the components and prevent the generation of abnormal noise. Although Figures 1 and 7 show the respective components engaged at their approximate centers in a straight line, the shape of the engagement may be a point or a line when viewed two-dimensionally, and the engagement may also be in a straight or curved line.

[0022] It is preferable that an opening 15d is provided in the first cover material 11. In the first embodiment, the ventilation mat 1 is placed on the back surface of the cushion material 64, and the opening 15d is provided in the first cover material 11, thereby forming a fan mounting hole.

[0023] The first cover material 11 has a peripheral edge 50 that extends slightly larger than the base material 12, and it is preferable that a slit is formed in the peripheral edge 50 from the outer periphery toward the center. This slit is preferable because it improves the ability to conform to the curved surface of the seat 60 when the ventilation mat 1 is installed on the front or back surface of the seat 60, and allows the entire peripheral edge 50 to be bonded to the cushion material 64.

[0024] In the first embodiment, nonwoven fabric is used for the first cover material 11, but it can be used without considering breathability or impermeability. In another embodiment, an impermeable material can also be used. However, it is also preferable that the first cover material 11 has high impermeability, since the peripheral edge 50 serves as a lid for the ventilation flow path (i.e., the base material 12) and prevents air from leaking from the ventilation flow path. When impermeability is important, it is also preferable to use a polyurethane film reinforced with polyester fiber.

[0025] In the first embodiment, the base material 12 and the first cover material 11 are mechanically fixed together by the engaging member 30. For example, if they are fixed together by adhesive or heat fusion, there is a risk that the adhesive or heat fusion portion will deteriorate and peel off in a high-temperature environment or over a long period of time, but this does not happen with the engaging member 30. Note that the base material 12 and the first cover material 11 do not need to be fixed together by one engaging member 30, and they may be fixed together by multiple engaging members 30. Of course, instead of fixing them with only one type of engaging member 30, it is also possible to fix them together by combining sewing thread, bannock pins, and stapler needles.

[0026] Next, a description will be given of how the ventilation mat 1 according to the first embodiment is incorporated into a seat 60. FIG. 3 shows a schematic cross-sectional view of a seat equipped with the ventilation mat according to the first embodiment. The seat 60 shown in FIG. 3 has a backrest 61 and a seat surface 62, and the ventilation mat 1 according to the first embodiment is installed on the underside of the seat surface 62. The ventilation mat 1 according to the first embodiment is actually installed on the underside of a cushion material 64, and is therefore installed on the seat 60 in a manner that is not visible to the seated occupant. In the first embodiment, as shown in FIG. 3, the ventilation guide 22 or a formed through-hole (not shown) is connected to the fan 40, which serves as an air blowing source, via the base material 12 and the opening 15d. The fan 40 is attached to a seat frame 67 by a blower attachment 46.

[0027] Furthermore, since the ventilation mat 1 according to the first embodiment is formed by combining parts with simple shapes, the efficiency of material utilization of the components of the ventilation mat 1 is high (for example, the ratio of usable material to waste material in one material is high). In other words, by increasing the efficiency of material utilization, the ventilation mat 1 according to the first embodiment can reduce manufacturing costs.

[0028] (Second embodiment) As shown in FIG. 2, the second embodiment adds a second cover material 21 to the first embodiment.

[0029] In the second embodiment, the ventilation mat 1 includes a base material 12, a first cover material 11, and a second cover material 21. It is also conceivable that openings 15a to 15d may be formed in the first cover material 11 and the second cover material 21. The openings 15a to 15c shown in FIG. 2 are openings provided on the side closer to the seated occupant, and opening 15d is an opening provided on the side farther from the seated occupant. The openings 15a to 15c are provided for sucking air from a predetermined location into the ventilation mat 1, or for sending air from the ventilation mat 1 to a predetermined location. The opening 15d is provided for connecting the fan 40 to the base material 12, etc.

[0030] As in the first embodiment, the second cover material 21 is preferably engaged with other components by an engaging member 30. As shown in FIG. 2, the engaging locations are preferably near the outer periphery of each component (not shown). Engaging near the outer periphery secures the components that are particularly subject to pressure when the human body is seated, suppressing friction between the components and preventing noise. Engaging near the outer periphery also suppresses curling of the component edges during the manufacturing process, improving manufacturing efficiency. In the second embodiment, the outer peripheries of the first cover material 11 and the second cover material 21 are defined as the portions that overlap with the outer periphery of the base material 12. The portions of each component that are not the outer periphery are defined as the central portions.

[0031] 2, the second cover material 21 has roughly the same area as the base material 12, but in reality, any area is acceptable. When engaging the various components described above, the second cover material 21 is provided to ensure stable engagement by preventing sewing threads or bannock pins from getting caught on the base material 12. The second cover material 21 only needs to have an area for hooking the engaging components, and may have a shape that only has an outer periphery or a shape that only has a center.

[0032] (Third embodiment) Furthermore, the present invention is not limited to the above-described embodiments and can be modified as appropriate without departing from the spirit and scope of the present invention. For example, as an alternative to the first and second embodiments, there is a third embodiment shown in FIGS. 4 and 5, in which the ventilation mat 1 can be placed on the front side of the cushion material 64, rather than on the back side of the cushion material 64. In the third embodiment, the first cover material 11 and the second cover material 21 are preferably made of a material that is less likely to generate noise when in contact with the base material 12 and that does not cause discomfort when seated. Furthermore, the ventilation mat 1 of the present invention can be placed on the backrest 61 side, rather than on the seat surface 62 side, or can be placed on both the seat surface 62 side and the backrest 61 side.

[0033] In the first to third embodiments, there is only one ventilation mat, but for example, a first ventilation mat and a second ventilation mat may be connected by a connecting mat. This connecting mat may have the same structure as the ventilation mat. Of course, there may be one connecting mat, or two or more connecting mats. There may also be a third or fourth ventilation mat.

[0034] The first cover material 11 and the second cover material 21 can be made of, for example, nonwoven fabric, spunbond nonwoven fabric, woven fabric, film, or rubberized fabric. Possible materials for the nonwoven fabric, spunbond nonwoven fabric, and woven fabric include aramid fiber, glass fiber, cellulose fiber, nylon fiber, vinylon fiber, acrylic fiber, polyester fiber, polyethylene fiber, polypropylene, polyolefin fiber, and rayon fiber. Possible materials for the film include polyethylene, polyvinyl, polypropylene, PET, vinyl chloride, polyurethane, and various thermoplastic elastomers. Films reinforced with various fibers may also be used. Rubberized fabric is fabric that has been processed to provide airtightness. Flame-retardant nonwoven fabrics are also preferred. Because nonwoven fabrics are fabrics, they do not generate noise when rubbing against other materials. Among fabrics, nonwoven fabrics are best able to achieve this effect. However, it is also preferable that the first cover material 11 has high impermeability from the viewpoint of suppressing air leakage from the ventilation flow path, since the peripheral edge portion 50 serves as a lid for the ventilation flow path (i.e., the base material 12). When impermeability is important, it is also preferable to use a polyurethane film reinforced with polyester fiber.

[0035] Examples of the substrate 12 include three-dimensional knitted fabrics made by knitting fibers three-dimensionally, such as double Russell or 3D mesh sheets; structures made of intricately intertwined fibers in a three-dimensional manner; open-cell foam materials (sponges); and arrays of rubber tubes. Examples of three-dimensional knitted fabrics include Fusion (registered trademark) manufactured by Asahi Kasei Corporation, Swing Net (registered trademark) manufactured by Suminoe Textile Co., Ltd., 3mesh (registered trademark) manufactured by Muller Textiles, and Cubic Eye (registered trademark) manufactured by Unitika Ltd. Examples of structures made of three-dimensionally intertwined fibers include Breath Air (registered trademark) manufactured by Toyobo Co., Ltd. Examples of materials used to construct open-cell foam materials and rubber tubes include urethane, EPDM, chloroprene, isoprene, silicone, and various thermoplastic elastomers. These substrates 12 may also be directional, with some being more breathable and others being less breathable. For example, in the case of a three-dimensional knitted fabric, there are directions in which portions with a higher fiber density (more fibers) per cross section are formed intermittently, and directions in which portions with a lower fiber density (fewer fibers) are formed continuously. In this case, the lower the fiber density (fewer fibers), the easier it is to breathe. When using a substrate 12 with such directionality, it is preferable that the air flow direction, which is the direction in which ventilation actually occurs, is the same as the direction in the substrate 12 that facilitates ventilation, for example, the direction in which there are portions with a lower fiber density (fewer fibers).

[0036] In the third embodiment, the base material 12 is placed under the buttocks of the seated person as a component of the ventilation mat 1 without the cushion material 64 in between, and therefore it is preferable that the base material 12 has durability to withstand the pressure of sitting.

[0037] In the second and third embodiments, the ventilation section is exemplified as being made up of openings 15a to 15d for ventilating any desired location on the surface, but is not limited thereto. For example, it is also conceivable that the entire surface is covered by the first cover material 11 without any openings. Furthermore, the position, shape, and number of openings are also arbitrary and may be designed appropriately according to the required characteristics. In the second and third embodiments, openings are provided in both the first cover material 11 and the second cover material 21, but the position, shape, and number of openings are also arbitrary and may be designed appropriately according to the required characteristics. [Industrial Applicability]

[0038] As described above, the ventilation mat of the present invention minimizes attenuation of the airflow from the air source and has a degree of design flexibility that allows it to be applied to various seating configurations. Its applications include, in addition to automobile seats, vehicle seats such as motorcycles and railroad cars, child seats, seats for heavy civil engineering and construction machinery, seats on ships and aircraft, Ferris wheels at amusement parks, bleacher seats at various stadiums, viewing seats at theaters and movie theaters, benches installed in train stations, theme parks, outdoor parks, etc., sofas and legless chairs used in homes and offices, chairs in barber shops, and medical chairs used in various medical institutions. Furthermore, it can be widely used not only for seats but also for beds, strollers, etc. [Explanation of symbols]

[0039] 1 ventilation mat 11 First cover material 12 Base material 15a~15d opening 21 Second cover material 22 Ventilation guide (or through hole) 24 Fan mounting holes 30 Engagement member 40 fans 50 Periphery 60 seats 61 Backrest 62 seat 64 Cushioning material 65 Skin cover

Claims

1. A substrate having a breathable three-dimensional structure; a first cover material disposed on one surface of the substrate; A ventilation mat characterized in that the first cover material is slightly larger than the base material, and the first cover material has a peripheral portion extending beyond the base material.

2. The substrate has a second cover material disposed on a surface thereof on which the first cover material is not disposed. The ventilation mat according to claim 1.

3. The peripheral portion has adhesive properties. The ventilation mat according to any one of claims 1 and 2.

4. The substrate and either or both of the first cover material and the second cover material are engaged with each other by an engaging member. The ventilation mat according to any one of claims 1 and 2.

5. The portion engaged by the engaging member is near the outer periphery of the base material. The ventilation mat according to claim 4.

6. The location engaged by the engaging member is approximately the center of the base material. The ventilation mat according to claim 4.

7. The engaging member is a sewing thread. The ventilation mat according to claim 4.

8. The first cover material is provided with an opening. The ventilation mat according to claim 4.

9. The first cover material is characterized in that a notch extending from the outer periphery toward the center is formed in the peripheral edge portion extending from the base material. The ventilation mat according to claim 4.

10. A seat cushion material, a cover, and the ventilation mat according to claim 4, the seat cushion material and the ventilation mat are covered with the skin cover, A recess is formed in the seat cushion material, A seat in which the ventilation mat is disposed in the recess of the seat cushion material.

11. A seat cushion material, a cover, and the ventilation mat according to claim 4, The seat cushion material is covered with the skin cover, A through hole is formed in the seat cushion material, The seat has the ventilation mat connected to the through hole of the seat cushion material.

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