Vehicle seat

Abstract

To provide a vehicle seat which achieves improvement of seating comfort and efficiency of an electric component.SOLUTION: A vehicle seat S3 includes: a cushion body 12A formed of a foamed resin; a heater 41 (an electric component) disposed in the cushion body 12A; and a three dimensional net elastic body 30 formed in a planar shape. The three dimensional net elastic body 30 is disposed at a position facing the heater 41 (the electric component) in the cushion body 12A and impregnated with the foamed resin. The three dimensional net elastic body 30 which is disposed facing the heater 41 improves seating comfort and efficiency of the electric component.SELECTED DRAWING: Figure 16

Description

[Technical Field]

[0001] The present invention relates to a vehicle seat, and more particularly to a vehicle seat having a cushion body. [Background technology]

[0002] Patent Document 1 discloses a cushion body for a seat that is made of a fiber aggregate in which a large number of synthetic fibers are three-dimensionally entangled, and in which the intertwined portions of the large number of synthetic fibers are bonded with a thermoset urethane resin. Furthermore, vehicle seats equipped with heaters have been developed to warm seated occupants, and Patent Document 2 discloses a vehicle seat in which a fiber-based wadding material containing fibers with high thermal conductivity is laminated on a seat heater. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-240024 [Patent Document 2] Japanese Patent Application Publication No. 10-234516 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional vehicle seats do not consider improving the resilience or elasticity of the seat cushion or seat back. Therefore, even when electrical components such as a heater or a vibrating member are provided in the seat cushion or seat back, there has been a demand for a vehicle seat that achieves both improved comfort and increased efficiency of the electrical components.

[0005] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a vehicle seat that is comfortable to sit in while improving the efficiency of electrical components. [Means for solving the problem]

[0006] The above-mentioned problems are solved by the vehicle seat of the present invention, which comprises a cushion body formed from a foamed resin, an electrical component placed inside the cushion body, and a three-dimensional reticulated elastic body formed in a planar shape, wherein the three-dimensional reticulated elastic body is placed inside the cushion body in a position facing the electrical component and is impregnated with the foamed resin. By arranging the three-dimensional reticulated elastic body impregnated with foamed resin inside the cushion body in a position facing the electrical components, the cushion body can have higher resilience and elasticity than a cushion body made of foamed resin alone, resulting in a more comfortable sitting experience. In addition, by arranging the three-dimensional reticulated elastic body in a position facing the electrical components, the efficiency of the electrical components can be improved.

[0007] In the above configuration, the three-dimensional reticulated elastic body may be made of a fiber structure made of a plurality of fibers. When the three-dimensional reticulated elastic body is made of a fiber structure made of a plurality of fibers, it becomes easier for the foamed resin to be impregnated therein.

[0008] In the above configuration, the electrical component may be a heater. The three-dimensional mesh elastic body can efficiently transmit the heat generated by the heater.

[0009] In the above-described configuration, the three-dimensional reticulated elastic body may be disposed on the seating surface side of the electrical component, and a surface layer formed of the foamed resin may be laminated on the seating surface side of the three-dimensional reticulated elastic body. By laminating the surface layer on the seating surface side of the three-dimensional mesh elastic body, it is possible to reduce the discomfort caused by the electrical components and the three-dimensional mesh elastic body.

[0010] In addition, the electrical component may be a heater, the three-dimensional reticulated elastic body may be an insulating three-dimensional reticulated elastic body made of a plurality of fibers and constructed of a fiber structure having higher insulating properties than the cushion body, and the insulating three-dimensional reticulated elastic body may be arranged opposite the surface of the heater opposite to the seating surface side. By arranging the insulating three-dimensional mesh elastic body opposite the surface of the heater facing the seating surface, the heat generated by the heater can be efficiently transferred to the occupant.

[0011] In the above configuration, the heat insulating three-dimensional reticulated elastic body may be laminated and integrated with the heater. By laminating the heater and the insulating three-dimensional reticulated elastic body together, the process of aligning the heater and the insulating three-dimensional reticulated elastic body is no longer necessary when manufacturing the vehicle seat, improving assembly efficiency.

[0012] In addition, in the above configuration, the heat-insulating three-dimensional reticulated elastic body may be provided with a thermally conductive three-dimensional reticulated elastic body made of a fiber structure having a higher thermal conductivity than the fiber structure of the heat-insulating three-dimensional reticulated elastic body, the thermally conductive three-dimensional reticulated elastic body being arranged opposite the seating surface side of the heater, and the thermally conductive three-dimensional reticulated elastic body being laminated and integrated with the heater. The provision of a thermally conductive three-dimensional reticulated elastic body allows heat from the heater to be transmitted to the occupant. Furthermore, by laminating the heater and the thermally conductive three-dimensional reticulated elastic body together, the process of aligning the heater and the thermally insulating three-dimensional reticulated elastic body becomes unnecessary during the manufacture of the vehicle seat, improving assembly efficiency.

[0013] In the above configuration, the electrical component may be a notification means for notifying a seated occupant. The three-dimensional mesh elastic body allows the notification by the notification means to be efficiently transmitted to the occupant.

[0014] Furthermore, in the above configuration, the electrical component is a vibration device, the three-dimensional mesh elastic body is a hard three-dimensional mesh elastic body made up of a plurality of fibers and composed of a fiber structure harder than the cushion body, and the hard three-dimensional mesh elastic body is arranged opposite the surface of the vibration device on the side facing the seating surface. By arranging the hard three-dimensional mesh elastic body opposite the seating surface side of the vibration device, vibrations from the vibration device can be efficiently transmitted to the occupant.

[0015] In the above configuration, the hard three-dimensional reticulated elastic body may be laminated and integrated with the vibration device. By laminating them integrally, the step of aligning the vibration device and the hard three-dimensional reticulated elastic body is no longer necessary during the manufacture of the vehicle seat, improving the ease of assembly.

[0016] Furthermore, in the above configuration, a soft three-dimensional reticulated elastic body may be provided which is made of a fiber structure softer than the fiber structure of the hard three-dimensional reticulated elastic body, the soft three-dimensional reticulated elastic body being arranged opposite the seating surface side of the vibration device, and the soft three-dimensional reticulated elastic body being laminated and integrated with the vibration device. By arranging the soft three-dimensional mesh elastic body opposite the seating surface of the vibration device, vibrations from the vibration device can be efficiently transmitted to the occupant. Furthermore, by being laminated and integrated, the process of aligning the vibration device and the soft three-dimensional mesh elastic body is not required during the manufacture of the vehicle seat, improving assembly efficiency.

[0017] In the above configuration, the foamed resin may be made of biomass urethane. Even when biomass urethane is used as the foam resin, the three-dimensional mesh elastic body improves the resilience and makes the chair less likely to deform, reducing the feeling of hitting the bottom and improving sitting comfort. [Effects of the Invention]

[0018] According to the vehicle seat of the present invention, the three-dimensional reticulated elastic body impregnated with a foamed resin is disposed inside the cushion body in a position facing the electrical components, thereby increasing the resilience and elasticity and improving seating comfort compared to a cushion body made of foamed resin alone. Furthermore, by disposing the three-dimensional reticulated elastic body in a position facing the electrical components, the efficiency of the electrical components can be improved. Furthermore, the three-dimensional reticulated elastic body is made of a fiber structure made of a plurality of fibers, which facilitates impregnation with the foamed resin. Furthermore, the three-dimensional mesh elastic body can efficiently transmit the heat generated by the heater. Furthermore, by laminating a surface layer on the seating surface side of the three-dimensional mesh elastic body, it is possible to reduce discomfort caused by the electrical components and the three-dimensional mesh elastic body. In addition, by arranging the insulating three-dimensional mesh elastic body opposite the surface of the heater facing the seating surface, the heat generated by the heater can be efficiently transferred to the occupant. Furthermore, by laminating the heater and the insulating three-dimensional reticulated elastic body together, the process of aligning the heater and the insulating three-dimensional reticulated elastic body is no longer necessary when manufacturing the vehicle seat, improving assembly efficiency. Furthermore, by providing a thermally conductive three-dimensional reticulated elastic body, heat from the heater can be transmitted to the occupant. Furthermore, by laminating the heater and the thermally conductive three-dimensional reticulated elastic body together, the process of aligning the heater and the thermally insulating three-dimensional reticulated elastic body becomes unnecessary during the manufacture of the vehicle seat, improving assembly efficiency. Furthermore, by providing a three-dimensional mesh elastic body, the notification by the notification means can be efficiently transmitted to the occupant. Furthermore, since the hard three-dimensional mesh elastic body is arranged opposite the seating surface side of the vibration device, the vibrations produced by the vibration device can be efficiently transmitted to the occupant. By laminating the vibration device and the hard three-dimensional mesh elastic body together, the process of aligning the vibration device and the hard three-dimensional mesh elastic body is not required when manufacturing the vehicle seat, improving assembly efficiency. Furthermore, by arranging the soft three-dimensional mesh elastic body opposite the seating surface of the vibration device, vibrations from the vibration device can be efficiently transmitted to the occupant. Furthermore, by being integrated and laminated, the process of aligning the vibration device and the soft three-dimensional mesh elastic body is no longer necessary during the manufacture of the vehicle seat, improving assembly efficiency. Furthermore, even when biomass urethane is used as the foam resin, the three-dimensional mesh elastic body improves the resilience and makes the chair less likely to deform, reducing the feeling of hitting the bottom and improving comfort when sitting. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is a perspective view of a vehicle seat according to an embodiment of the present invention; [Figure 2] FIG. 2 is a cross-sectional view of the seat cushion taken along line II-II in FIG. [Figure 3] FIG. 2 is a cross-sectional view showing the configuration of a three-dimensional mesh elastic body. [Figure 4] 3 is an enlarged cross-sectional view of the seat cushion showing a portion A of FIG. 2. FIG. [Figure 5] FIG. 10 is a cross-sectional view showing a case where a load is applied to the seat cushion. [Figure 6A] FIG. 10 is a cross-sectional view showing another example of a seat cushion. [Figure 6B] FIG. 10 is a cross-sectional view showing another example of a seat cushion. [Figure 7] 3A and 3B are cross-sectional views showing the state before and after the three-dimensional reticulated elastic body is impregnated with a foamed resin. [Figure 8] FIG. 2 is a top view of the vehicle seat. [Figure 9] FIG. 1 is a side view of a vehicle seat. [Figure 10] FIG. 1 is a perspective view of a seat for a two-wheeled vehicle. [Figure 11A] FIG. 10 is a cross-sectional view showing an example in which a plurality of three-dimensional reticulated elastic bodies are combined. [Figure 11B] FIG. 10 is a cross-sectional view showing another example in which a plurality of three-dimensional mesh elastic bodies are combined. [Figure 12] 10 is a graph showing the relationship between the amount of deflection and the load. [Figure 13] FIG. 10 is a flow chart showing a method for manufacturing a cushion pad. [Figure 14A] FIG. 10 is a cross-sectional view showing a mold for the cushion pad, illustrating a state in which a three-dimensional mesh elastic body is disposed on the bottom surface. [Figure 14B]FIG. 10 is a cross-sectional view showing a mold for a cushion pad, illustrating a state in which a three-dimensional mesh elastic body is supported by pins. [Figure 15] FIG. 10 is a perspective view of a vehicle seat according to a second embodiment. [Figure 16] 16 is a cross-sectional view of the seat cushion taken along line XVI-XVI in FIG. 15. [Figure 17A] FIG. 10 is a cross-sectional view showing another example of a seat cushion. [Figure 17B] FIG. 10 is a cross-sectional view showing another example of a seat cushion. [Figure 18] FIG. 10 is a perspective view showing a vehicle seat according to a third embodiment. [Figure 19] 19 is a cross-sectional view of the seat cushion taken along line XIX-XIX in FIG. 18. [Figure 20] FIG. 10 is a cross-sectional view showing another example of a seat cushion. DETAILED DESCRIPTION OF THE INVENTION

[0020] <<First Embodiment>> The configuration of a vehicle seat according to a first embodiment (present embodiment) of the present invention will be described below with reference to the drawings. However, the embodiment described below is an example for facilitating understanding of the present invention and is not intended to limit the present invention. In other words, the present invention may be modified or improved without departing from the spirit thereof, and of course, the present invention also includes equivalents thereof.

[0021] In the following, an example of a vehicle seat will be a vehicle seat mounted on a ground-traveling vehicle having wheels such as an automobile or train, and an example of the configuration will be described. However, the present invention is not limited to vehicle seats, and may also be a seat mounted on an aircraft, ship, or other vehicle that moves other than on land.

[0022] In the following description, the "seat longitudinal direction" refers to the longitudinal direction of the vehicle seat, which coincides with the direction of travel when the vehicle is traveling. The "seat width direction" refers to the width direction of the vehicle seat, which coincides with the left-right direction as seen by an occupant seated in the vehicle seat. The "vertical direction" refers to the vertical direction of the vehicle seat, which coincides with the vertical direction when the vehicle is traveling on a horizontal plane. Furthermore, unless otherwise specified, the shape, position, and posture of each part of the vehicle seat described below will be described assuming that the vehicle seat is in an occupied state.

[0023] <Basic configuration of vehicle seat S1> The basic configuration of a vehicle seat according to this embodiment (hereinafter referred to as vehicle seat S1) will be described with reference to Fig. 1. Fig. 1 is a perspective view of the vehicle seat S1 as seen obliquely from the front. In Fig. 1, for convenience of illustration, upholstery materials 11 and 21 are removed from a portion of the vehicle seat S1.

[0024] The vehicle seat S1 is placed on the vehicle body floor FL and is a seat on which a vehicle occupant sits. In this embodiment, the vehicle seat S1 is used as a front seat corresponding to the front seat of the vehicle. However, the vehicle seat S1 is not limited to this, and may be a rear seat of the vehicle, or may be used as a middle seat in the second row or a rear seat in the third row in a vehicle having three rows of seats in the front-to-rear direction.

[0025] As shown in FIG. 1, the vehicle seat S1 mainly comprises a seat cushion 1, which serves as the seating portion that supports the buttocks of a seated occupant H (hereinafter sometimes referred to as the occupant), a seat back 2, which serves as the backrest that supports the back of the occupant, and a headrest 3, which is disposed above the seat back 2 and supports the head of the occupant. The seat cushion 1 and the seat back 2 are connected to each other with a reclining device 6 sandwiched therebetween. The reclining device 6 supports the seat back 2 relative to the seat cushion 1 so that the seat back 2 can be tilted. A rail device 4 (see FIG. 9) is provided below the seat cushion 1, and the rail device 4 fixes the vehicle seat S1 to the vehicle floor FL in a state in which the vehicle seat S1 can slide back and forth.

[0026] A frame (not shown) that serves as the skeleton of the vehicle seat S1 is provided within the vehicle seat S1. The frame is mainly composed of a cushion frame that serves as the skeleton of the seat cushion 1 and a back frame that serves as the skeleton of the seat back 2.

[0027] The seat cushion 1 is composed of a cushion pad 12 and a skin material 11 that covers the outer surface of the cushion pad 12. The seat back 2 is composed of a back pad 22 and a skin material 21 that covers the outer surface of the back pad 22. The cushion pad 12 and the back pad 22 correspond to the cushion body of the present invention.

[0028] The cushion pad 12 and the back pad 22 are made of urethane resin (foamed resin) such as soft polyurethane foam. More specifically, they are urethane base materials that are foam-molded by injecting unfoamed urethane resin (urethane foaming agent) into a mold. The cushion pad 12 and the back pad 22 are cushion bodies made of soft urethane resin, and have appropriate cushioning properties, and support the seated occupant H while deflecting under the load of the occupant H. Note that the composition of the soft polyurethane foam used in the cushion pad 12 and the back pad 22 is generally known, and therefore a detailed description thereof will be omitted. The cushion pad 12 and the back pad 22 may be made of biomass urethane. Biomass urethane is a urethane foam containing raw materials including biomass resources such as renewable plants.

[0029] The cover material 11 for the seat cushion 1 and the cover material 21 for the seat back 2 are made of cloth, film, leather, etc. The cover materials 11, 21 are attached so as to cover the cushion pad 12 and the back pad 22 in a stretched state with a predetermined tension applied.

[0030] The seat cushion 1 of this embodiment includes a three-dimensional mesh elastic body 30 formed in a planar shape within the cushion pad 12. The three-dimensional mesh elastic body 30 is disposed in predetermined regions within the cushion pad 12, such as regions that support the ischial bones and thighs of the occupant H from below and regions that support the thighs from the sides. The three-dimensional mesh elastic body 30 is disposed within the cushion pad 12 in a state in which it is impregnated with urethane resin.

[0031] The seat back 2 also includes a three-dimensional mesh elastic body 30 formed in a planar shape within the back pad 22. The three-dimensional mesh elastic body 30 of the seat back 2 is disposed in predetermined regions within the back pad 22, such as a region that supports the back of the occupant H from behind and a region that supports the torso from the sides. The three-dimensional mesh elastic body 30 is disposed within the back pad 22 in a state where it is impregnated with a foam resin such as a urethane resin.

[0032] Hereinafter, within the seat cushion 1, the region that supports the ischial bones and thighs of the occupant H from below will be referred to as the base portion 15, and the regions on the outer sides of the base portion 15 that support the thighs of the occupant H from the sides will be referred to as the side portions 16. Additionally, within the seat back 2, the region that supports the back of the occupant H from behind will be referred to as the base portion 25, and the region that supports the torso of the occupant H from the sides will be referred to as the side portions 26. The side portions 16, 26 are so-called bank portions.

[0033] <Three-dimensional mesh elastic body> The three-dimensional reticulated elastic body 30 will be described with reference to Fig. 3. Fig. 3 is a cross-sectional view of the three-dimensional reticulated elastic body 30. The three-dimensional reticulated elastic body 30 is composed of a fiber structure made up of a plurality of fibers. As shown in Fig. 3, the three-dimensional reticulated elastic body 30 used in this embodiment has a three-layer structure, and is composed of a surface layer 31, a back layer 32, and an intermediate layer 33 connecting the surface layer 31 and the back layer 32.

[0034] The surface layer 31 and the back layer 32 may be formed of, for example, a cloth in which a plurality of fibers are woven. Alternatively, the surface layer 31 and the back layer 32 may be formed of a nonwoven fabric in which fibers are intertwined. The intermediate layer 33 is a structure having a mesh-like structure that expands three-dimensionally while forming interconnected voids. The structure of the intermediate layer 33 is configured to exhibit elasticity with the mesh-like structure. Urethane resin is filled into the voids in the mesh-like structure of the intermediate layer 33, and the elasticity of the urethane resin also contributes to the function. Therefore, the three-dimensional mesh elastic body 30 impregnated with urethane resin has higher resilience and elasticity than a portion simply composed of urethane resin.

[0035] The three-dimensional reticulated elastic body 30 is completed by injecting and foaming unfoamed urethane resin raw material so that it penetrates into the voids in the fiber structure that forms the intermediate layer 33. In other words, the three-dimensional reticulated elastic body 30 provided in the cushion pad 12 and the back pad 22 is formed by foam molding the surrounding area made of urethane resin simultaneously, with the urethane resin foaming occurring while a portion of the urethane resin penetrates into the intermediate layer 33. The three-dimensional reticulated elastic body 30 is positioned and fixed at the desired position within the mold that molds the cushion pad 12 or the back pad 22, and is molded integrally with the surrounding urethane resin through normal foam molding.

[0036] The intermediate layer 33 can be formed of a fiber structure using, for example, fibers made of a thermoplastic resin. This fiber structure is formed by forming a large number of loops using thermoplastic resin fibers, which are then three-dimensionally and randomly intertwined, and then bonding the contacting portions of the fibers together using heat. Examples of thermoplastic resin materials include polyester-based resins, polyamide-based resins, polyether-based resins, and polyolefin-based resins. As such, the intermediate layer 33 is formed of a plurality of fiber structures, and therefore is easily impregnated with urethane resin.

[0037] The intermediate layer 33 using fibers made of thermoplastic resin is just an example, and other structures may be used. For example, the intermediate layer 33 may be realized by a plurality of threads connecting the front layer 31 and the back layer 32.

[0038] The thickness of the three-dimensional reticulated elastic body 30 after it has been impregnated with the urethane resin can be adjusted by adjusting the amount of longitudinal expansion of the intermediate layer 33. Adjusting the amount of expansion also allows for adjustment of the fiber density. By making the fiber density of the intermediate layer 33 relatively high, it is possible to form a relatively hard three-dimensional reticulated elastic body 30. Furthermore, by making the fiber density of the intermediate layer 33 lower than that of an intermediate layer 33 with a high fiber density, it is possible to form a softer three-dimensional reticulated elastic body. In other words, the hardness of the three-dimensional reticulated elastic body 30 can be adjusted by adjusting the fiber density. Hereinafter, the three-dimensional reticulated elastic body 30 having a relatively high fiber density will be referred to as a high-density three-dimensional reticulated elastic body 30A, and the three-dimensional reticulated elastic body 30 having a relatively low fiber density will be referred to as a low-density three-dimensional reticulated elastic body 30B. The elasticity of the three-dimensional reticulated elastic body 30 may be adjusted by the amount of stretch of the fibers contained in the intermediate layer 33.

[0039] Furthermore, it is preferable that the thickness of the three-dimensional network elastic body 30 be greater before and after impregnation with the urethane resin. The upper part of Fig. 7 shows the three-dimensional network elastic body 30 before impregnation with the urethane resin, and the lower part of Fig. 7 shows the three-dimensional network elastic body 30 disposed within the cushion body and impregnated with the urethane resin. As shown in Fig. 7, the thickness T1 of the three-dimensional network elastic body 30 in the impregnated state is configured to be greater than the thickness T0 of the three-dimensional network elastic body 30 before impregnation with the urethane resin. The thickness of the three-dimensional network elastic body 30 increases when it is impregnated with the urethane resin, thereby increasing its elasticity and improving its cushioning properties.

[0040] In FIG. 3, the intermediate layer 33 is specifically depicted as a plurality of intertwined fibers, but in FIG. 2 and FIG. 4 onward, the intermediate layer 33 is depicted as a pattern of crossing diagonal lines.

[0041] In the past, when a load was applied to the seat cushion 1, the cushion pad 12 was significantly deformed, which could cause a feeling of hitting the bottom. When the three-dimensional mesh elastic body 30 impregnated with urethane resin is provided as in the present embodiment, the resilience and elasticity of that portion are increased. Therefore, as shown in FIG. 5 , even when a load (arrow B) from an occupant is applied to the cushion pad 12 with the three-dimensional mesh elastic body 30 disposed inside the cushion pad 12, a resilience in the upward direction (arrow C direction) is generated. The increased resilience and elasticity make it less likely that a feeling of hitting the bottom will occur, improving cushioning properties, and therefore improving the seating comfort of the seat cushion 1.

[0042] The position of the three-dimensional reticulated elastic body 30 in the seat cushion 1 will be described using Figures 2 and 4 to 6. In Figure 2, the upper side is the seating surface 17 side of the seat cushion 1. As shown in Figures 2 and 4, the cushion pad 12 of the seat cushion 1 is composed of a main body portion 14, a three-dimensional reticulated elastic body 30 laminated on the seating surface side of the main body portion 14, and a surface layer portion 13 laminated on the seating surface side of the three-dimensional reticulated elastic body 30. The main body portion 14 and the surface layer portion 13 are made only of urethane resin. A skin material 11 is arranged on the seating surface side of the surface layer portion 13. The surface layer portion 13 corresponds to the surface layer of the present invention.

[0043] As described above, the three-dimensional mesh elastic body 30 comprises a surface layer 31, a back layer 32, and an intermediate layer 33 provided between the surface layer 31 and the back layer 32, and the three-dimensional mesh elastic body 30 is arranged in a state impregnated with urethane resin.

[0044] The three-dimensional mesh elastic body 30 is disposed inside the cushion pad 12 on the seating surface side of the seat cushion 1. In other words, the three-dimensional mesh elastic body 30 is disposed close to the seating surface 17 of the cushion pad 12. By disposing the three-dimensional mesh elastic body 30 on the seating surface side, the effect of increasing the elasticity of the three-dimensional mesh elastic body 30 when the occupant H sits on it is strengthened, improving cushioning properties, thereby improving the feel of the surface of the seat cushion 1 and the sitting comfort.

[0045] Additionally, a surface layer 13 made of urethane resin is laminated on the seating surface side of the three-dimensional mesh elastic body 30. By providing the surface layer 13, for example, the discomfort caused by the three-dimensional mesh elastic body 30 is reduced, and the feel of the surface of the seat cushion 1 and the sitting comfort are improved.

[0046] It is also preferable that the thickness T1 of the three-dimensional reticulated elastic body 30 is greater than the thickness T2 of the surface layer portion 13. By making the thickness T1 of the three-dimensional reticulated elastic body 30 greater than the thickness T2 of the surface layer portion 13, it is possible to further improve the resilience and hysteresis loss rate.

[0047] As shown in FIG. 6A, the surface layer portion 13 may not be provided, and the three-dimensional mesh elastic body 30 may be disposed on the surface of the cushion pad 12 so as to come into direct contact with the cover material 11.

[0048] 6B , the three-dimensional mesh elastic body 30 may be disposed adjacent to the surface of the cushion pad 12 opposite the surface on the seating side. That is, the three-dimensional mesh elastic body 30 is disposed on the bottom side of the cushion pad 12. Disposing the three-dimensional mesh elastic body 30 in this manner reduces discomfort caused by the three-dimensional mesh elastic body 30, and also suppresses deformation of the bottom side of the cushion pad 12 by the three-dimensional mesh elastic body 30, making it less likely for the seat cushion 1 to feel like it is bottoming out, improving the seating comfort of the seat cushion 1.

[0049] <Effect of the three-dimensional mesh elastic body 30> Here, the effect of the three-dimensional mesh elastic body 30 will be described with reference to Fig. 5 and Fig. 12. As shown in Fig. 5, when a load is applied to the cushion pad 12, a repulsive force is generated by the three-dimensional mesh elastic body 30, which can suppress deformation of the cushion pad 12. Therefore, for example, even when the same load is applied to the cushion pad 12, the amount of deflection of the cushion pad can be reduced. Furthermore, by providing the three-dimensional mesh elastic body 30, the hysteresis loss rate (the ratio of the difference in workload between pressurization and depressurization to the workload during pressurization) can be improved. FIG. 12 is a graph showing the relationship between load and deflection. In the graph of FIG. 12, the solid line indicates the case where the cushion pad 12 is made of urethane resin only, and the dotted line indicates the case where urethane resin is combined with the three-dimensional mesh elastic body 30. The combination of the three-dimensional mesh elastic body 30 and urethane resin reduces and improves the hysteresis loss rate compared to the case where urethane resin is used alone. Note that, although the above description has focused on the effect of the three-dimensional mesh elastic body 30 in relation to the seat cushion 1, the same effect is obtained when the three-dimensional mesh elastic body 30 is provided in the seat back 2.

[0050] Furthermore, by arranging a plurality of three-dimensional mesh elastic bodies 30 one on top of the other in the vertical direction, as in the seat cushion 1D shown in FIG. 11A, the repulsive force and elasticity can be further increased. 11B, three-dimensional mesh elastic bodies 30 having different fiber densities may be arranged at the same distance D from the seating surface 17 of the seat cushion 1. In FIG. 12B, a high-density three-dimensional mesh elastic body 30A and a low-density three-dimensional mesh elastic body 30B are arranged at the same distance D from the seating surface 17. In other words, the high-density three-dimensional mesh elastic body 30A and the low-density three-dimensional mesh elastic body 30B are arranged in the same layer. By combining three-dimensional mesh elastic bodies 30 with different specifications in the same layer, different properties can be exhibited in different parts of the seat cushion 1.

[0051] <Arrangement of the three-dimensional mesh elastic body 30> As described above, the hardness of the three-dimensional reticulated elastic body 30 can be adjusted by adjusting the fiber density. Specifically, increasing the fiber density results in a hard three-dimensional reticulated elastic body (high-density three-dimensional reticulated elastic body 30A), while decreasing the fiber density results in a soft three-dimensional reticulated elastic body (low-density three-dimensional reticulated elastic body 30B).

[0052] Seating comfort can be optimized by appropriately arranging three-dimensional mesh elastic bodies 30 with different hardness in the seat cushion 1 and the seat back 2. For example, since the low-density three-dimensional mesh elastic body 30B is soft and highly elastic, it is recommended to arrange it in a high-load area where the load of the occupant H is directly applied. That is, it is recommended to arrange the low-density three-dimensional mesh elastic body 30B in the base portion 15 of the seat cushion 1 that directly supports the seated occupant. In particular, as shown in FIG. 9 , it is recommended to arrange the low-density three-dimensional mesh elastic body 30B in an area of ​​the base portion 15 that supports the ischial bones of the occupant H. By arranging the low-density three-dimensional mesh elastic body 30B in the base portion 15, the resilience and hysteresis loss rate of the cushion pad 12 are improved, and the feeling of hitting the bottom is eliminated. When the three-dimensional mesh elastic body 30 is arranged on the base portion 15 of the seat cushion 1, it is preferable to arrange it so as to avoid the hanging groove. In the case of the seat back 2, it is preferable to place it on the base portion 25 of the seat back 2 that directly supports the back of the occupant H. By placing it in this manner, it is possible to improve the seating comfort.

[0053] The high-density three-dimensional mesh elastic body 30A is preferably disposed in the side portion 16 that is disposed on the outer side in the seat width direction of the base portion 15 of the seat cushion 1. In particular, the high-density three-dimensional mesh elastic body 30A is preferably disposed in an area that supports the sides of the thighs of the occupant H. By providing the high-density three-dimensional mesh elastic body 30A in the side portion 16, hardening of the side portion 16 is promoted, the lower body of the occupant H, especially the thighs, are firmly supported, and the stability of the seat cushion 1 is improved. In the case of the seat back 2, it is advisable to place it on the side portion 26 of the seat back 2 that supports the torso of the occupant H. This promotes hardening of the side portion 26, and the upper body of the occupant H is supported from the side, improving the stability of the seat back 2.

[0054] <Biomass Urethane> The cushion pad 12 and back pad 22 are made of soft urethane resin, but in recent years, biomass urethane (biopolyol, etc.) has been used in some cases for environmental reasons. However, pads made of biomass urethane have low resilience or elasticity and are subject to large deformations. This can lead to a feeling of bottoming out, resulting in poor seating comfort. Furthermore, these pads require more manufacturing processes than usual. Even when the seat cushion 1 and back pad 22 of this embodiment are made of biomass urethane, the resilience and elasticity are increased by impregnating them with the three-dimensional mesh elastic body 30. Therefore, even when biomass urethane is used instead of urethane resin, a vehicle seat S1 with improved sitting comfort can be provided.

[0055] <Motorcycle seat S2> Another example of the vehicle seat S1 will be described with reference to FIG. 10 . FIG. 10 is a perspective view showing a motorcycle vehicle seat S2, which is another example of the vehicle seat S1. The vehicle seat S2 is a straddle-type seat including a seat cushion 1C. The seat cushion 1C includes a bottom plate 7 and a cushion pad 12A disposed on the bottom plate 7. A cover material 11 is also provided to cover the cushion pad 12A. In the vehicle seat S2, a low-density three-dimensional mesh elastic body 30B is disposed in a portion that forms the base portion 15 on which the occupant H sits, more specifically, in a portion below the occupant H's ischial bones. The disposition of the low-density three-dimensional mesh elastic body 30B improves resilience and eliminates the feeling of bottoming out. In addition, a high-density three-dimensional mesh elastic body 30A is disposed in a side portion 16 located on the side of the base portion 15 in the seat width direction. This promotes hardening of the side portion 16, improving stability when held between the legs.

[0056] <Manufacturing method> A manufacturing method of the vehicle seat S1 including the cushion pad 12 will be described using Fig. 13 and Figs. 14A and 14B. Fig. 13 is a flow chart showing a manufacturing method of the cushion pad 12 of the vehicle seat S1. Fig. 14A is a cross-sectional view showing the mold 50 for the cushion pad 12, illustrating a state in which the three-dimensional reticulated elastic body 30 is placed on the bottom surface, and Fig. 14B is a cross-sectional view showing the mold for the cushion pad, illustrating a state in which the three-dimensional reticulated elastic body 30 is supported by pins.

[0057] When manufacturing a vehicle seat S1, first, a mold 50 for the seat cushion 1, which will become the cushion body, is prepared (step S101). Next, as shown in FIG. 14A, a three-dimensional reticulated elastic body 30 is placed on the bottom surface of the mold 50 at a position that will become a predetermined area of ​​the seat cushion 1 (step S102). When providing a surface layer portion 13 on the seat cushion 1, pins 51 that support the three-dimensional reticulated elastic body 30 are placed as shown in FIG. 14B. Next, unfoamed urethane resin is supplied to the mold 50 (step S103). At this time, the unfoamed urethane resin is injected into the three-dimensional reticulated elastic body 30. Note that the three-dimensional reticulated elastic body 30 is raised by the pins 51, and if there is space below, the urethane resin is poured into that space. The thickness T2 of the surface layer portion 13 can be adjusted by changing the height of the pins 51. The height L of the pins 51 is preferably adjusted between 0 and 20 mm. After supplying the unfoamed urethane resin, the urethane resin is foamed to form the cushion pad 12 (step S104). The back pad 22 of the seat back 2 is formed in the same manner. The cushion pad 12 and the back pad 22 are placed on the frame, and the upholstery materials 11, 21 are then placed on top to complete the vehicle seat S1.

[0058] <<Second embodiment>> A vehicle seat S3 of a second embodiment will be described with reference to Fig. 15 to Fig. 17B. Fig. 15 is a perspective view of the vehicle seat S3 of the second embodiment. Fig. 16 is a cross-sectional view taken along line XVI-XVI in Fig. 15, showing a seat cushion 1F. Figs. 17A and 17B are cross-sectional views showing other examples of the seat cushion 1F (seat cushions 1G and 1H).

[0059] The vehicle seat S3, like the vehicle seat S1 of the first embodiment, is placed on the vehicle body floor FL and is a seat on which a vehicle occupant sits. Its main components are a seat cushion 1F, a seat back 2F, and a headrest 3. The vehicle seat S3 also includes a heater 41 (electrical component) in the base portion 15 of the seat cushion 1F and the base portion 25 of the seat back 2. In the following description, components that are the same as or equivalent to those in the vehicle seat S1 of the first embodiment are designated by the same reference numerals, and their description will be omitted.

[0060] The seat cushion 1F of the vehicle seat S3 has a cushion pad 12F made of soft urethane resin (foamed resin). As shown in Fig. 16, the cushion pad 12F has therein a heater 41 (electrical component) and a planar three-dimensional mesh elastic body 30. The three-dimensional mesh elastic body 30 is disposed inside the cushion pad 12F at a position facing the heater 41, and is impregnated with urethane resin.

[0061] The heater 41 is composed of a base fabric and an electric heating wire that serves as a heat source and is arranged on the base fabric, and its configuration is generally known, so a description thereof will be omitted. The three-dimensional reticulated elastic body 30, which is disposed in a position facing the heater 41, is composed of three layers: a surface layer 31, a back layer 32, and an intermediate layer 33, and is composed of a fiber structure made of a plurality of fibers, similar to the three-dimensional reticulated elastic body 30 of the vehicle seat S1 of the first embodiment. Since the other main structures are similar, detailed explanations will be omitted.

[0062] As described above, the three-dimensional mesh elastic body 30 is disposed inside the cushion pad 12F at a position facing the heater 41. More specifically, the cushion pad 12F has a heat-insulating three-dimensional mesh elastic body 30C disposed at a position facing the surface 41b of the heater 41 opposite the surface 41a on the seating surface side. The heat-insulating three-dimensional mesh elastic body 30C is made of a fiber structure having higher heat insulating properties than the urethane resin of the cushion pad 12F. The provision of the heat-insulating three-dimensional mesh elastic body 30C makes it difficult for heat from the heater 41 to be transferred to the main body portion 14 of the cushion pad 12F, and instead the generated heat is transferred to the occupant side.

[0063] The cushion pad 12F includes a thermally conductive three-dimensional reticulated elastic body 30D with high conductivity. The thermally conductive three-dimensional reticulated elastic body 30D is disposed on the seating surface side of the heater 41 in a position facing the heater 41. The thermally conductive three-dimensional reticulated elastic body 30D is made of a fiber structure with higher thermal conductivity than the fiber structure of the heat-insulating three-dimensional reticulated elastic body 30C. The thermally conductive three-dimensional reticulated elastic body 30D may be made of a fiber structure with higher thermal conductivity than urethane resin. By disposing the thermally conductive three-dimensional reticulated elastic body 30D on the seating surface side of the heater 41, heat generated by the heater 41 can be conducted more efficiently.

[0064] Furthermore, both the thermally conductive three-dimensional reticulated elastic body 30D and the thermally insulating three-dimensional reticulated elastic body 30C serve as the three-dimensional reticulated elastic body 30, and thus have the effect of improving the resilience and elasticity of the cushion pad 12F, thereby improving the sitting comfort. Therefore, the vehicle seat S3 improves the sitting comfort while enhancing the functionality of the heater 41 through the cushion pad 12F.

[0065] The heat insulating three-dimensional reticulated elastic body 30C and the heat conductive three-dimensional reticulated elastic body 30D may be laminated integrally with the heater 41. By laminating them integrally, the number of manufacturing steps for the cushion pad 12F can be reduced, and assembly can be improved. This configuration in which the heater 41 is sandwiched between the heat insulating three-dimensional reticulated elastic body 30C and the heat conductive three-dimensional reticulated elastic body 30D may be applied to the back pad 22 of the seat back 2F.

[0066] As shown in FIG. 17A, the heat-conductive three-dimensional mesh elastic body 30D may not be provided on the seating surface side of the heater 41, and only the heat-insulating three-dimensional mesh elastic body 30C may be provided opposite the surface of the heater 41 opposite to the seating surface side. Also, as in the seat cushion 1H shown in FIG. 17B, the heat insulating three-dimensional reticulated elastic body 30C may not be provided, and only the heat conductive three-dimensional reticulated elastic body 30D may be provided opposite the seating surface side of the heater 41. In this case, a surface layer 13 made of urethane resin may be laminated on the seating surface side of the thermally conductive three-dimensional reticulated elastic body 30D.

[0067] <<Third Embodiment>> A vehicle seat S4 of a third embodiment will be described with reference to Fig. 18 to Fig. 20. Fig. 18 is a perspective view of the vehicle seat S4 of the third embodiment. Fig. 19 is a cross-sectional view of the seat cushion 1I taken along line XIX-XIX in Fig. 18. Fig. 20 is a cross-sectional view showing another example (seat cushion 1J) of the seat cushion 1I.

[0068] The vehicle seat S4, like the vehicle seat S1 of the first embodiment, is placed on the vehicle body floor FL and is a seat on which a vehicle occupant H sits. The vehicle seat S4 mainly comprises a seat cushion 1I, a seat back 2I, and a headrest 3. The vehicle seat S4 also includes a vibration device 43 (electrical component) on a base portion 15 of the seat cushion 1I and a base portion 25 of the seat back 2I.

[0069] The vibration device 43 is a notification means that mainly notifies the seated occupant H of warnings and the like by applying vibrations to the occupant H. The vibration device 43 is composed of a case and an eccentric motor that is housed in the case and generates vibrations. The vibration device 43 is a commonly known device, so a detailed description will be omitted. A harness extends from the eccentric motor of the vibration device 43 and is connected to an ECU (not shown) mounted on the vehicle, making it possible for the ECU to control the strength and timing of vibrations of the vibration device 43. The vibration device 43 is mainly used to notify warnings and the like, but the method of use of the vibration device 43 is not limited to this, and it may also be used to knead the thighs or back of the occupant H. In the following description, the same or equivalent members as those in the vehicle seat S1 of the first embodiment are given the same numbers, and the description thereof will be omitted.

[0070] The seat cushion 1I of the vehicle seat S4 has a cushion pad 12I made of soft urethane resin (foamed resin). As shown in Fig. 19, the cushion pad 12I includes a vibrating device 43 (electrical component) and a planar three-dimensional mesh elastic body 30 therein. The three-dimensional mesh elastic body 30 is disposed inside the cushion pad 12I at a position facing the vibrating device 43, and is impregnated with urethane resin.

[0071] In addition, the three-dimensional mesh elastic body 30 arranged in a position opposite the vibration device 43 is composed of three layers, namely, a surface layer 31, a back layer 32, and an intermediate layer 33, similar to the three-dimensional mesh elastic body 30 of the vehicle seat S1 of the first embodiment, and is composed of a fiber structure made of multiple fibers.

[0072] As described above, the three-dimensional mesh elastic body 30 is disposed inside the cushion pad 12I at a position facing the vibrating device 43. More specifically, as shown in Fig. 19 , the cushion pad 12I has a hard three-dimensional mesh elastic body 30E disposed at a position facing the surface 43b opposite to the surface 43a on the seating surface side of the vibrating device 43. In other words, the hard three-dimensional mesh elastic body 30E is disposed at a position facing the lower surface of the vibrating device 43.

[0073] The hard three-dimensional mesh elastic body 30E is composed of a fiber structure made of a material harder than the urethane resin that constitutes the cushion pad 12I. The hard three-dimensional mesh elastic body 30E may be made harder by increasing the fiber density of the intermediate layer 33. By positioning the hard three-dimensional mesh elastic body 30E in a position facing the surface 43b opposite the surface 43a on the seating surface side of the vibration device 43, the vibration transmission of the vibration device 43 can be increased, and notifications can be transmitted by vibration more reliably.

[0074] 19, the cushion pad 12I includes a soft three-dimensional mesh elastic body 30F that is softer than the hard three-dimensional mesh elastic body 30E. The soft three-dimensional mesh elastic body 30F is disposed at a position facing the vibrating device 43 on the surface 43a of the vibrating device 43 that faces the seating surface.

[0075] The soft three-dimensional mesh elastic body 30F is made of a fiber structure made of a material softer than the fiber structure making up the hard three-dimensional mesh elastic body 30E. It may also be made of a fiber structure made of a material softer than the urethane resin making up the cushion pad 12B. The soft three-dimensional mesh elastic body 30F may also be softened by lowering the fiber density of its intermediate layer 33. By arranging the soft three-dimensional mesh elastic body 30F on the seating surface side of the vibrating device 43, vibrations generated by the vibrating device 43 can be transmitted more efficiently.

[0076] The hard three-dimensional mesh elastic body 30E may be laminated integrally with the vibrating device 43. The soft three-dimensional mesh elastic body 30F may also be laminated integrally with the vibrating device 43. By laminating them integrally, the process of overlapping the three-dimensional mesh elastic body 30 and the vibrating device 43 is eliminated when manufacturing the cushion pad 12I, improving assembly efficiency.

[0077] Furthermore, both the hard three-dimensional mesh elastic body 30E and the soft three-dimensional mesh elastic body 30F serve as the three-dimensional mesh elastic body 30, enhancing the resilience and elasticity of the cushion pad 12I and improving the sitting comfort. Therefore, the vehicle seat S4 improves the sitting comfort while enhancing the function of the vibration device 43 through the cushion pad 12I. The configuration in which the vibration device 43 is sandwiched between the hard three-dimensional mesh elastic body 30E and the soft three-dimensional mesh elastic body 30F may also be applied to the back pad 22 of the seat back 2I.

[0078] The arrangement of the three-dimensional mesh elastic body 30 inside the cushion pad 12I is not limited to this, and as shown in the cushion pad 12J of the seat cushion 1J shown in Figure 20, only the hard three-dimensional mesh elastic body 30E may be arranged to face the surface 43b opposite to the surface 43a on the seating surface side of the vibration device 43.

[0079] 19, the hard three-dimensional mesh elastic body 30E has the same hardness in all regions, but the hardness may be varied depending on the region. For example, the hard three-dimensional mesh elastic body 30E may be made the hardest in the region facing the surface 43b opposite to the seating surface 43a of the vibration device 43, and the hardness may be made the next hardest in the region facing the side surface 43c of the vibration device 43. The soft three-dimensional mesh elastic body 30F is formed so that it is softest in the area facing the seating surface 43a of the vibrating device 43, and next softest in the area facing the side surface 43c of the vibrating device 43. By changing the hardness depending on the facing surface in this way, it becomes possible to transmit vibrations more efficiently.

[0080] Cushion pad 12J having vibrating device 43 is made of soft urethane, but may be made of biomass urethane. Although the use of biomass urethane increases the deformation of cushion pad 12J, the provision of three-dimensional mesh elastic body 30 inside increases the resilience and elasticity, making it less likely for the cushion pad to hit the bottom, and improving sitting comfort.

[0081] Furthermore, in the vehicle seats S3 and S4 of the second and third embodiments, the heater 41 and the vibration device 43 are used as electrical components, but the electrical components are not limited to the heater or the vibration device 43. The electrical components may also be sensors capable of acquiring biological information of the seated occupant H. For example, the electrical components may be seating sensors that acquire the seating state or breathing sensors that measure the breathing state of the occupant H.

[0082] The electrical component may be a movable member that can be switched between a first state and a second state different from the first state. More specifically, the movable member that is an electrical component may be an air cushion that expands or contracts inside the seat cushion 1 or the seat back 2 by injecting or discharging a fluid. [Explanation of symbols]

[0083] S1~S4 Vehicle seats 1. 1A~1J seat cushion 2, 2F, 2I seat backs 3 Headrest 4 Rail device 6 Reclining device 7 Bottom Plate 11 Skin material 12, 12A, 12B, 12F, 12I, 12J Cushion pad (cushion body) 13 Surface layer part (surface layer) 14 Main body part 15 Base 16 Side part 17 Seating surface 21 Skin material 22 Back pad (cushion body) 25 Base 26 Side part 30 Three-dimensional mesh elastic body 30A High density three-dimensional mesh elastic body 30B Low density three-dimensional mesh elastic body 30C Thermal insulating three-dimensional mesh elastic body 30D Thermally conductive three-dimensional mesh elastic material 30E Hard three-dimensional mesh elastic body 30F Soft three-dimensional mesh elastic body 31 Surface layer 32 Back layer 33 Middle Class 41 Heater (electrical parts) 41a Seat side surface 41b Opposite side 43 Vibration device (electrical components) 43a Seat side surface 43b Opposite side 43c side 50 molds 51 pin

Claims

1. A vehicle seat, a cushion body formed of foam resin; an electrical component disposed inside the cushion body; a three-dimensional mesh elastic body formed in a planar shape, The vehicle seat is characterized in that the three-dimensional mesh elastic body is disposed inside the cushion body at a position facing the electrical component, and is impregnated with the foamed resin.

2. 2. The vehicle seat according to claim 1, wherein the three-dimensional mesh elastic body is made of a fiber structure made of a plurality of fibers.

3. 2. The vehicle seat according to claim 1, wherein the electrical component is a heater.

4. the three-dimensional mesh elastic body is disposed on the seating surface side of the electrical component, 4. The vehicle seat according to claim 3, wherein a surface layer made of the foamed resin is laminated on the seating surface side of the three-dimensional reticulated elastic body.

5. the electrical component is a heater, the three-dimensional reticulated elastic body is a heat insulating three-dimensional reticulated elastic body made of a fiber structure that is made of a plurality of fibers and has higher heat insulating properties than the cushion body, 2. The vehicle seat according to claim 1, wherein the heat insulating three-dimensional mesh elastic body is disposed opposite to the seating surface of the heater.

6. 6. The vehicle seat according to claim 5, wherein the heat insulating three-dimensional reticulated elastic body is laminated and integrated with the heater.

7. a thermally conductive three-dimensional reticulated elastic body made of a fiber structure having a higher thermal conductivity than the fiber structure of the thermally insulating three-dimensional reticulated elastic body; the thermally conductive three-dimensional mesh elastic body is disposed opposite to the seating surface side of the heater, 6. The vehicle seat according to claim 5, wherein the heat-conductive three-dimensional reticulated elastic body is laminated and integrated with the heater.

8. 2. The vehicle seat according to claim 1, wherein the electrical component is a notification means for notifying a seated occupant.

9. the electrical component is a vibration device, the three-dimensional mesh elastic body is made of a plurality of fibers and is a hard three-dimensional mesh elastic body made of the fiber structure harder than the cushion body, 2. The vehicle seat according to claim 1, wherein the hard three-dimensional mesh elastic body is disposed opposite to the seating surface side of the vibration device.

10. 10. The vehicle seat according to claim 9, wherein the hard three-dimensional mesh elastic body is laminated and integrated with the vibration device.

11. a soft three-dimensional reticulated elastic body made of a fiber structure softer than the fiber structure of the hard three-dimensional reticulated elastic body; the soft three-dimensional mesh elastic body is disposed opposite to the seating surface side of the vibration device, 11. The vehicle seat according to claim 10, wherein the soft three-dimensional mesh elastic body is laminated and integrated with the vibration device.

12. 2. The vehicle seat according to claim 1, wherein the foamed resin is made of biomass urethane.

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