Vehicle seat and method for manufacturing the vehicle seat

Abstract

To provide a vehicle seat that can prevent performance degradation of an air flow generating device by suppressing application of an excessive load of a seated person to the air flow generating device while arranging the air flow generating device inside a seat back. [Solution] A vehicle seat S includes a headrest 3 and a seat back 2 that supports the headrest 3. The headrest 3 is attached to the seat back 2 so that an upper end of the headrest 3 protrudes forward from a seating surface S1 of the seat back 2, and the seat back 2 has a blower device 100 that generates an airflow below the headrest 3, and the lower end of the headrest 3 overlaps with the blower device 100 in a front view.

Description

[Technical Field]

[0001] The present invention relates to a vehicle seat and a method for manufacturing the vehicle seat, and more particularly to a vehicle seat provided with an air flow generating device and a method for manufacturing the vehicle seat. [Background technology]

[0002] Conventionally, a vehicle seat has been proposed that includes a blower and an air outlet that blows air from the blower toward a seated occupant. Specifically, the blower is provided inside a seat cushion (sitting portion) or a seat back (backrest portion) that supports the weight of an occupant, and multiple air outlets that blow air toward the buttocks or back of the occupant are formed in the seat cushion and the seat back, and ventilation paths through which air passes between the blower and the air outlets are formed in the seat cushion and the seat back. This allows the occupant seated in the vehicle seat to spend the travel time until they reach their destination comfortably while receiving the blower.

[0003] Patent Document 1 discloses a vehicle seat in which a blower is disposed above the vertical center of the seat back. A typical seat back is configured to deflect backward when a seat occupant leans against the seat back and absorb the weight of the seat occupant. Therefore, by disposing the blower above the vertical center of the seat back, it is possible to prevent the rotation of the blower from being hindered by the weight of the seat occupant when the seat occupant leans against the seat back. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-291310 Summary of the Invention [Problem to be solved by the invention]

[0005] The technology described in Patent Document 1 has the effect of suppressing the performance degradation of the air blower caused by the weight of the seated passenger being applied to the air blower. However, in recent years, as seat backs have become lighter and thinner, there has been a demand for further suppression of the load applied to the air blower in order to suppress the performance degradation of the air blower disposed inside the seat back.

[0006] The present invention has been made in consideration of the above-mentioned problems, and its purpose is to provide a vehicle seat that can position an air flow generating device inside the seat back while preventing the seated person from applying excessive load to the air flow generating device, thereby preventing a decrease in the performance of the air flow generating device. [Means for solving the problem]

[0007] The above problem is solved by the vehicle seat of the present invention, which is a vehicle seat including a headrest and a seat back that supports the headrest, wherein the headrest is attached to the seat back at an upper end thereof so as to protrude forward from the seating surface of the seat back, and the seat back has an air flow generating device that generates an air flow below the headrest, and the lower end of the headrest overlaps the air flow generating device in a front view.

[0008] According to the above configuration, the headrest is attached to the seat back so as to protrude forward from the seating surface of the seat back and is positioned so as to overlap the airflow generating device in a front view. As a result, the padding of the seat back and the padding of the headrest are located on the seating surface side of the airflow generating device. Therefore, the two paddings can reduce the load of the seated occupant applied to the airflow generating device. Furthermore, because the headrest protrudes forward from the seating surface of the seat back, the weight of the occupant when seated in the vehicle seat can be distributed and supported by the headrest and the seat back. This reduces the load on the seat back relatively, preventing excessive load from being applied by the occupant to the airflow generating device located inside the seat back, thereby preventing a decrease in the performance of the airflow generating device.

[0009] The airflow generating device may have a plurality of rotating blades that rotate around a rotation axis extending in the front-to-rear direction, and the lower end of the headrest may overlap with at least one of the rotating blades when viewed from the front. According to the above configuration, the headrest is positioned so as to overlap the rotating blades of the airflow generating device when viewed from the front. As a result, the weight of the seated occupant is distributed and supported by the headrest and the seat back, and the rotating blades of the airflow generating device are covered by the headrest. This prevents the occupant from exerting excessive weight on the airflow generating device located inside the seat back, and also prevents the rotating blades, which are relatively weak among the components of the airflow generating device, from being damaged by the occupant's weight.

[0010] The lower end of the headrest may be positioned above the rotation axis. According to the above configuration, the lower end of the headrest is positioned above the rotation axis of the airflow generating device. As a result, the rotation axis of the airflow generating device is not covered by the headrest. This prevents the seat occupant from applying excessive weight to the airflow generating device located inside the seat back, and also prevents the performance of the airflow generating device from being reduced due to the headrest covering the front of the airflow generating device.

[0011] The headrest may also have a headrest frame that forms the skeleton of the headrest, a padding material that covers the front of the headrest frame, and a cover member that covers the headrest frame from the rear, and the lower end of the headrest frame may be positioned above the air flow generating device. According to the above configuration, the highly rigid headrest frame covers the front of the air flow generating device, making it possible to prevent the performance of the air flow generating device from being reduced due to the weight of the seated person's head being applied to the air flow generating device via the headrest frame.

[0012] The lower end of the cover member may be positioned above the airflow generating device. According to the above configuration, the lower end of the cover member that covers the headrest from behind is positioned higher than the upper end of the airflow generating device. As a result, even if the cover member is made of synthetic resin and is not breathable, the lower end of the cover member is positioned higher than the upper end of the airflow generating device, making it possible to prevent the cover member from causing a decrease in the performance of the airflow generating device.

[0013] The seat back may have a bracket that protrudes forward from the seating surface, and the headrest may be attached to a front surface of the bracket via the headrest frame. According to the above configuration, the headrest frame, which forms the framework of the headrest, is positioned forward of the seating surface of the seatback, allowing the entire headrest to protrude significantly forward of the seating surface. This effectively distributes and supports the occupant's weight between the headrest and the seatback, reducing the relative load on the seatback. This also prevents the occupant from exerting excessive weight on the airflow generating device located inside the seatback, thereby preventing a decrease in the performance of the airflow generating device.

[0014] In addition, the airflow generating device may be fixed to the seat back by a fixing member that fixes the airflow generating device to the seat back, and a lower end of the headrest may overlap the fixing member in a front view. According to the above configuration, the fixing member that fixes the airflow generating device to the seat back is covered from the front by the headrest, so that even if the fixing member protrudes forward beyond the airflow generating device, it is possible to prevent the occupant from feeling a foreign body sensation when seated.

[0015] The airflow generating device may have a connector that allows a connection cable electrically connected to the airflow generating device to be inserted or removed, and the lower end of the headrest may be positioned above the connector. According to the above configuration, the connector is not covered from the front by the headrest, which prevents the headrest from covering the front of the connector, thereby preventing a decrease in workability during inspection of the airflow generating device, which involves inserting and removing the connection cable.

[0016] Furthermore, the above-mentioned problem is solved by a method for manufacturing a vehicle seat of the present invention, which is a method for manufacturing a vehicle seat including a headrest and a seat back that supports the headrest, comprising: attaching an air flow generating device that generates an air flow to the seat back; and attaching the headrest to an upper end of the seat back so that it protrudes forward from the seating surface of the seat back; and wherein, when the headrest is attached to the seat back, the lower end of the headrest overlaps with the air flow generating device in a front view.

[0017] According to the above configuration, the headrest is attached to the seat back so as to protrude forward from the seating surface of the seat back and is positioned so as to overlap the airflow generating device in a front view. As a result, the padding of the seat back and the padding of the headrest are located on the seating surface side of the airflow generating device. Therefore, the two paddings can reduce the load of the seated occupant applied to the airflow generating device. Furthermore, because the headrest protrudes forward from the seating surface of the seat back, the weight of the occupant when seated in the vehicle seat can be distributed and supported by the headrest and the seat back. This reduces the load on the seat back relatively, preventing excessive load from being applied by the occupant to the airflow generating device located inside the seat back, thereby preventing a decrease in the performance of the airflow generating device. [Effects of the Invention]

[0018] According to the present invention, it is possible to position an air flow generating device inside the seat back while preventing excessive load from being applied to the air flow generating device by the seated person, thereby preventing a decrease in the performance of the air flow generating device. Furthermore, it is possible to prevent the rotor blades, which have a relatively low strength among the components of the airflow generating device, from being damaged by the weight of a seated person. Furthermore, it is possible to prevent the performance of the airflow generating device from being reduced due to the headrest covering the front of the airflow generating device. It is also possible to prevent a decrease in performance of the airflow generating device caused by the load of the seated occupant's head being applied to the airflow generating device via the headrest frame. Furthermore, it is possible to prevent the cover member from causing a decrease in the performance of the airflow generating device. Furthermore, even if the fixing member protrudes forward from the airflow generating device, it is possible to prevent the occupant from feeling a foreign body sensation when seated. Furthermore, it is possible to prevent the headrest from covering the front of the connector, which would otherwise reduce the efficiency of inserting and removing the connection cable. [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, as viewed obliquely from the front. [Figure 2] FIG. 2 is a perspective view of the vehicle seat as seen obliquely from the rear. [Figure 3] FIG. 2 is an exploded perspective view of the seat cushion as seen obliquely from the front. [Figure 4] FIG. 2 is an exploded perspective view of the seat back as seen obliquely from the front. [Figure 5] FIG. 2 is an exploded perspective view of the seat back module as seen obliquely from the front. [Figure 6] FIG. 2 is an exploded perspective view of the headrest as seen obliquely from the front. [Figure 7] FIG. 2 is a perspective view of the seat back module as seen obliquely from the rear. [Figure 8] FIG. 2 is a front view of the first back cover to which the blower device is attached. [Figure 9] FIG. 10 is an enlarged view of a main part of the first back cover to which the blower device is attached. [Figure 10] FIG. 4 is a diagram for explaining a load applied to the blower device. [Figure 11] FIG. DETAILED DESCRIPTION OF THE INVENTION

[0020] Hereinafter, an embodiment of the present invention will be described with reference to FIGS. In the vehicle seat S of this embodiment, the headrest 3 is attached to the upper end of the seat back 2 so as to protrude forward (toward the seated person) beyond the seating surface 2d of the seat back 2. In this case, the lower end of the headrest 3 is positioned so as to overlap the blower device 100 in a front view. This prevents excessive load from being applied by the seated person to the blower device 100, thereby preventing a decrease in performance of the blower device 100.

[0021] The configuration of a vehicle seat S according to one embodiment of the present invention will be described below with reference to the drawings. However, the embodiment described below is intended to facilitate 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. In the following description, the descriptions regarding the materials, shapes, and sizes of the seat components are merely examples and do not limit the present invention.

[0022] In the following description, the "seat front-rear direction" refers to the front-rear direction of the vehicle seat S, which is the direction that coincides with the front-rear direction as seen by an occupant seated in the vehicle seat S. The "seat width direction" refers to the width direction of the vehicle seat S, which is the direction that coincides with the left-right direction as seen by an occupant seated in the vehicle seat S. The "up-down direction" refers to the up-down direction of the vehicle seat S, which is the direction that coincides with the vertical direction when the vehicle is traveling on a horizontal plane. The term "outside" simply refers to the side closer to the outside in the direction from the center of the vehicle seat S to the outside, and the term "inside" refers to the side closer to the center in the direction from the outside to the center of the vehicle seat S.

[0023] <Overall structure of vehicle seat S> FIG. 1 is a perspective view of a vehicle seat S seen obliquely from the front, and FIG. 2 is a perspective view of the vehicle seat S seen obliquely from the rear. As shown in FIGS. 1 and 2, a vehicle seat S according to this embodiment includes a seat cushion 1, a seat back 2, a headrest 3, a rail device 4, and a reclining device 5 as main components.

[0024] <<Seat cushion 1>> The seat cushion 1 is a support member that supports the buttocks of a seated occupant, supporting the seated occupant from below. The seat cushion 1 mainly comprises a seat cushion frame 10 (see FIG. 3) that forms the framework of the seat cushion 1, and a seat cushion module 1M that is replaceably attached to the seat cushion frame 10.

[0025] The seat cushion frame 10 is a frame body having a rectangular shape when viewed from above. The seat cushion frame 10 has left and right side frames 11, a pan frame 12 connecting the front ends of the left and right side frames 11, and a rear connecting frame 13 connecting the rear ends of the left and right side frames 11. The seat cushion frame 10 also has a support plate 15 connected to the rear connecting frame 13 via elastic springs 14 and supported by the left and right side frames 11. The support plate 15 is a flexible pressure-receiving member that receives the load of a seated occupant applied via a seat cushion module 1M, which will be described later. Cushion module assembly portions 16 are provided on both sides in the seat width direction in front of the pan frame 12. The cushion module assembly portions 16 can be connected to assembly portions 24 formed on a cushion base cover 20 of a seat cushion module 1M, which will be described later. This makes it possible to assemble the seat cushion module 1M to the seat cushion frame 10 in a replaceable manner. The seat cushion frame 10 constitutes a seat frame F together with a seat back frame 30 and a headrest frame 70, which will be described later.

[0026] The seat cushion module 1M mainly comprises a cushion base cover 20, a first pad material 1a, a second pad material 1b, and a cover material 1c (see FIG. 1). The seat cushion module 1M functions as a seat portion of the vehicle seat S by being attached to a seat cushion frame 10. In addition, the seat cushion module 1M can be removed and replaced, making it possible to easily change the design and functionality of the vehicle seat S, and to configure a vehicle seat S that is optimal for each seated occupant.

[0027] The cushion base cover 20 has a rectangular shape in top view and includes left and right cover side portions 21, a cover front portion 22, and a cover rear portion 23. The cover front portion 22 is provided with an assembly portion 24 for fixing the cushion base cover 20 to the pan frame 12, and the cover rear portion 23 is provided with a frame detachable portion 25 that detachably engages with the rear connecting frame 13. Therefore, the cushion base cover 20 can be attached to the seat cushion frame 10 by engaging the frame detachable portion 25 with the rear connecting frame 13 and assembling the assembly portion 24 to the pan frame 12.

[0028] A control device 90 that controls the vehicle seat S is attached below the cushion base cover 20 via a bracket 91. The control device 90 is an ECU (Electronic Control Unit) that acquires output signals from detection sensors (such as temperature sensors) built into the vehicle, and controls a blower device 100 and a seat heater 110 (described later) based on the output signals to improve the comfort of an occupant sitting in the vehicle seat S.

[0029] The first pad material 1a and the second pad material 1b are cushion materials that are placed on the cushion base cover 20 and cover the cushion base cover 20. The first pad material 1a and the second pad material 1b are foamed resin molded bodies that have different properties (breathability and flexibility). By stacking multiple foamed resin molded bodies with different properties in this way, it is possible to improve seating comfort and comfort while reducing manufacturing costs. The skin material 1c is made of a stretchable synthetic leather material and covers the first pad material 1a and the second pad material 1b.

[0030] <<Seat back 2>> The seat back 2 is a support member that supports the back of a seated occupant from behind. The seat back 2 has a seat back frame 30 (see FIG. 4) that forms the framework, a seat back module 2M that is replaceably attached to the seat back frame 30 from the front, and a second back cover 50 that covers the seat back 2 from the rear.

[0031] The seatback frame 30 is a frame body having a substantially rectangular shape in a front view. The seatback frame 30 has left and right backside frames 31, an upper frame 32 connecting the upper ends of the left and right backside frames 31, and a lower frame 33 connecting the lower ends of the left and right backside frames 31.

[0032] The backside frames 31 are elongated frame members that extend vertically and are arranged apart from each other while facing each other in the seat width direction. Each backside frame 31 is an angle member formed by bending a plate-like body vertically, and the front edge is bent outward to improve the strength of the backside frame 31. A reclining body 5a, a back rotation shaft 5b, and a spiral spring 5c ​​(see FIG. 1) of the reclining device 5, which will be described later, are attached to the lower end of the back side frame 31.

[0033] The upper frame 32 is a frame having a substantially inverted U shape, and connects the upper ends of the left and right back side frames 31. The upper frame 32 is made of a round pipe material. Four module assembly parts 34 are provided on the upper frame 32 and are arranged at approximately equal intervals. The module assembly parts 34 protrude outward from the upper frame 32 and are assembled to a cover assembly part 45 (see FIG. 7) provided on the first back cover 40 (described later) and an assembly part 55 provided on the second back cover 50 by being connected and fixed thereto.

[0034] The lower frame 33 is a long frame member extending laterally, connecting the lower ends of the left and right back side frames 31. The lower frame 33 has a recess formed by bending a plate-like body so as to be recessed downward. The back rotation shaft 5b of the reclining device 5, which will be described later, is housed inside the recess.

[0035] Fig. 5 shows an exploded perspective view of the seatback module 2M. As shown in Fig. 5, the seatback module 2M mainly comprises a first back cover 40, a first padding material 2a, a second padding material 2b, a seat heater 110, and an upholstery material 2c (see Fig. 1). The seatback module 2M functions as a backrest portion of the vehicle seat S by being attached to the seatback frame 30. In addition, the seatback module 2M can be removed and replaced, making it possible to easily change the design and functionality of the vehicle seat S, and to configure a vehicle seat S that is optimal for each seated occupant. In recent years, attention has been focused on technology for thinning the seat back 2 in order to reduce the weight of the seat back 2. The seat back module 2M of this embodiment has a built-in blower device 100, and while improving the comfort of the occupant seated in the seat back 2, it has a smaller dimension in the seat thickness direction than a conventional seat back 2, achieving a thinner seat back. The blower device 100 will be described later.

[0036] The first back cover 40 is a cover member that supports electrical components built into the seat back module 2M and protects the electrical components by covering the seat back module 2M from the rear. Specifically, the seat back module 2M supports a blower device 100, an electric motor 108 (see FIG. 7), and a seat heater 110, which will be described later. The first back cover 40 has a cover body 40a made of synthetic resin and a first opening 44 formed in approximately the center of the cover body 40a. The cover body 40a has an outer dimension slightly larger than the seat back frame 30, and is provided on the back side with a back reinforcing rib 40b that improves the strength of the cover body 40a, and a cover assembly part 45 that is fixed to the module assembly part 34 of the seat back frame 30.

[0037] The first opening 44 is formed in a position facing the pressure-receiving plate 60 attached to the front side of the first back cover 40. Therefore, when the weight of the seated occupant is applied to the pressure-receiving plate 60, the pressure-receiving plate 60 can deform rearward in accordance with the posture of the seated occupant's back and waist. The cover main body 40a has left and right cover side portions 41 on the outer sides of the first opening 44 in the seat width direction, an upper cover portion 42 on the upper side, and a lower cover portion 43 on the lower side.

[0038] The left and right cover side portions 41 extend in the vertical direction and are recessed rearward on the inside. The left and right cover side portions 41 are connected to the plate mounting portion 61 of the pressure-receiving plate 60 to support the left and right side edges of the pressure-receiving plate 60. An electric motor 108 is attached to and supported on the back side of the cover side portion 41 located on the right side when viewed from the front.

[0039] As shown in Fig. 5, the cover upper portion 42 has a generally triangular shape that protrudes upward, and its ends in the seat width direction connect the upper ends of the left and right cover side portions 41. A bracket 46 to which the headrest 3 is attached is fixed to the upper end of the cover upper portion 42. As will be described later with reference to Fig. 11, the bracket 46 protrudes forward from the cover upper portion 42, and the headrest 3 can be fixed to the upper end of the seat back 2 so that it protrudes forward (toward the seat occupant) from the seating surface 2d.

[0040] A blower device 100 is attached below the bracket 46. The blower device 100 generates an airflow that draws air in from the front of the seat back 2 and blows the air downward at the rear (back side). As will be described later, the front of the blower device 100 is covered by the first padding 2a and the second padding 2b of the seat back 2 and the padding 3a of the headrest 3. This prevents the weight of the seated occupant from being applied to the blower device 100 while the blower device 100 is built into the seat back 2. Details of the headrest 3 and the weight of the seated occupant that is applied to the blower device 100 will be described later. The blower device 100 corresponds to an airflow generating device.

[0041] The cover lower portion 43 extends in the seat width direction, and connects the lower ends of the left and right cover side portions 41 at both ends in the seat width direction. The cover lower portion 43 supports the lower end of the pressure-receiving plate 60. Front reinforcing ribs 40c for improving the strength of the first back cover 40 are provided on the front sides of the cover side portions 41, the cover upper portion 42, and the cover lower portion 43.

[0042] The first padding material 2a and the second padding material 2b are cushioning materials that are placed on the first back cover 40 and cover the first back cover 40. The first padding material 2a and the second padding material 2b are foamed resin molded bodies that have different properties (breathability and flexibility) from each other. The first pad material 2a is formed with a blower covering portion 2aa that faces the blower device 100, and a space that can supply air to an area facing an intake port 102 of the blower device 100 (described later) is provided.

[0043] The seat heater 110 is an electric heating wire heater that receives electrical energy via a heater connection cable 130 and heats the back and waist of an occupant seated in the vehicle seat S. The skin material 2c is made of a stretchable synthetic leather material and covers the first pad material 2a and the second pad material 2b.

[0044] 4, the second back cover 50 covers the entire seat back 2 from the rear. More specifically, the second back cover 50 and the seat back module 2M are fixed together with the seat back frame 30 sandwiched between them in the front-rear direction, thereby assembling the seat back 2. The second back cover 50 has a cover body 50a made of synthetic resin and a second opening 54 formed in approximately the center of the cover body 50a. The cover body 50a protects the seat back module 2M by covering the first back cover 40 from the rear, and serves to improve the strength of the seat back 2. An assembly portion 55 is provided on the front side of the second back cover 50 to be fixed to the module assembly portion 34 of the seat back frame 30.

[0045] The second opening 54 is formed at a position and with dimensions approximately equal to those of the first opening 44 of the first back cover 40, allowing the pressure plate 60 to deform rearward in accordance with the posture of the occupant's back and waist when the weight of the occupant is applied to the pressure plate 60. The cover main body 50a has left and right cover side portions 51 on both sides of the second opening 54 in the seat width direction, an upper cover portion 52 above, and a lower cover portion 53 below. The left and right cover side portions 51, upper cover portion 52, and lower cover portion 53 of the second back cover 50 respectively cover the left and right cover side portions 41, upper cover portion 42, and lower cover portion 43 of the first back cover 40 from behind.

[0046] <<Headrest 3>> The headrest 3 is a support member that supports the head of a seated occupant from behind. As shown in Fig. 6, the headrest 3 mainly comprises a headrest frame 70 that forms the skeleton of the headrest 3, a padding material 3a, a covering material 3b (see Fig. 1), and a headrest cover 80.

[0047] The headrest frame 70 is a plate-like body having a substantially rectangular shape in a front view, and includes a frame main body 71 and an outer edge flange 72 that is bent rearward at the outer edge of the frame main body 71 relative to the frame main body 71. A bracket assembly part 73 that is attached to a bracket 46 fixed to the seat back 2 is provided in the center of the frame main body 71, and is fixed to the front surface 46a of the bracket 46 by inserting a fastener (screw) therethrough. Furthermore, cover assembly parts 74 are provided at the four corners (upper right, upper left, lower right, and lower left) of the frame main body 71, to which a headrest cover 80 that covers the rear of the headrest frame 70 is attached. The headrest frame 70 and the headrest cover 80 are assembled by the cover assembly parts 74 engaging with assembly parts 84 provided on the headrest cover 80.

[0048] The headrest cover 80 covers the headrest frame 70 from behind, and forms the outer shell of the headrest 3 by being attached to the headrest frame 70. The headrest cover 80 has approximately the same outer dimensions as the headrest frame 70, and includes a cover main body 81 and an outer edge flange 82 that is bent forward relative to the cover main body 81 at the outer edge of the cover main body 81.

[0049] An attachment opening 83 that allows the bracket 46 to pass through is formed in the approximate center of the headrest cover 80. This allows the bracket 46 and the bracket assembly portion 73 to be joined and connected, making it possible to attach the headrest 3 to the first back cover 40 of the seat back 2. In addition, assembly portions 84 are provided at the four corners (upper right, upper left, lower right, and lower left) of the headrest cover 80 to engage the headrest cover 80 with the headrest frame 70. The assembly portions 84 protrude forward and can engage with the cover assembly portions 74 of the headrest 3.

[0050] The pad material 3a is a cushion material that covers the front of the headrest frame 70. The pad material 3a is a flexible foamed resin molded body. The covering material 3b (see FIG. 1) is made of a stretchable synthetic leather material and covers the entire headrest 3.

[0051] <<Rail device 4>> Returning to Fig. 1, the rail device 4 connects the vehicle seat S to the floor of the vehicle so that the seat S can slide in the front-rear direction. The rail device 4 has a known structure (the structure of a general slide rail mechanism). In detail, the rail device 4 has a lower rail 4a fixed to the floor and an upper rail 4b that can slide in the front-rear direction relative to the lower rail 4a.

[0052] The rail device 4 also includes a locking member 4c that locks the upper rail 4b against sliding movement relative to the lower rail 4a. The upper rail 4b is normally locked by the locking member 4c in a state where it cannot slide relative to the lower rail 4a. When the passenger performs a predetermined operation, the upper rail 4b transitions to an unlocked state where it can slide relative to the lower rail 4a. The locking member 4c has a known locking mechanism.

[0053] <<Reclining device 5>> The reclining device 5 rotatably connects the seat back 2 to the seat cushion 1. More specifically, the seat back 2 can be displaced between an upright position in which the seat back 2 is upright, a forward tilted position in which the seat back 2 is tilted forward, and a backward tilted position in which the seat back 2 is tilted backward.

[0054] The reclining device 5 has a known reclining mechanism. Specifically, the reclining device 5 has a reclining main body 5a that is driven to rotate the seat back 2, a back rotation shaft 5b, and a spiral spring 5c ​​that biases the seat back frame 30 forward around the back rotation shaft 5b.

[0055] <Blower device 100> Next, the blower device 100 will be described in detail with reference to FIGS. The blower device 100 has a blower body 101, an inlet 102 formed in front of the blower body 101, and an outlet 103 formed on the lower side with an opening facing rightward. In other words, by rotating the blower body 101, the blower device 100 draws air from the front (in the direction from the seating surface 2d toward the inlet 102) and generates an airflow that flows downward (in the direction from the cover upper portion 42 toward the first opening 44). This allows the blower device 100 to draw in warm air warmed by the body temperature of the seated occupant and send it out toward the bottom of the vehicle seat S, thereby improving the comfort of the occupant sitting in the vehicle seat S.

[0056] Figure 9 is an enlarged view of the main part of Figure 8. Blower body 101 is a propeller fan and has a rotary shaft 101a extending in the front-to-rear direction and a plurality of rotary blades 101b that rotate around rotary shaft 101a. However, the present invention is not limited to this, and blower body 101 may also be a sirocco fan.

[0057] Furthermore, the blower device 100 is electrically connected to a blower connection cable 120 that supplies electrical energy to the blower device 100 via a blower connection connector 121. Therefore, when inspecting the blower device 100, the inspection of the blower device 100 can be easily performed by pulling out the blower connection cable 120 from the blower device 100 and connecting an inspection cable.

[0058] Next, we will explain the mounting structure of the blower device 100. As described above, the blower device 100 is supported by the first back cover 40 of the seat back module 2M. To explain in more detail, the blower device 100 is mounted on the cover upper portion 42 of the first back cover 40.

[0059] The cover upper portion 42 has a flat plate portion 42a and a blower device accommodating recess 42b located below the flat plate portion 42a. The flat plate portion 42a has an umbrella shape that protrudes upward and has a flat surface that is flat in the sheet thickness direction.

[0060] The blower device-accommodating recess 42b forms a recess recessed rearward from the flat plate portion 42a (see FIGS. 10 and 11), and the blower device 100 is accommodated inside the recess and fixedly supported therein. As a result, the blower device 100 is disposed rearward from the flat surface of the flat plate portion 42a. The blower device-accommodating recess 42b is located below the bracket 46 to which the headrest 3 is attached and above the pressure-receiving plate 60. In other words, the blower device 100 is disposed at a position that avoids the bracket 46 and the pressure-receiving plate 60, to which a large load is applied when an occupant sits in the vehicle seat S.

[0061] Additionally, an upper reinforcement rib 42c is provided behind the blower device accommodating recess 42b to improve the strength of the cover upper portion 42. The upper reinforcement rib 42c is an orthogonal rib consisting of a vertical reinforcement rib 42c1 extending vertically through the cover upper portion 42 and a horizontal reinforcement rib 42c2 extending in the seat width direction, which intersect at right angles. The blower device 100 is fixed at the intersection where the vertical reinforcement rib 42c1 and the horizontal reinforcement rib 42c2 intersect at right angles. More specifically, the blower device 100 is fixed to the upper reinforcement rib 42c by a blower device fixing portion 104. The blower device fixing portion 104 has a first blower device fixing portion 104a, a second blower device fixing portion 104b, and a third blower device fixing portion 104c that protrude upward, downward, and leftward from the blower device 100, and is fixed to the intersection of the upper reinforcement ribs 42c by fasteners (screws). This makes it possible to improve the strength of the cover upper part 42 while realizing a reduction in the weight and thickness of the seat back 2, and further makes it possible to stably fix the blower device 100 to the cover upper part 42. The blower device fixing part 104 corresponds to a fixing member.

[0062] Next, the positional relationship between the blower device 100 and the headrest 3 and the fact that this reduces the load of the seated person applied to the blower device 100 will be described. 8 and 9, the lower end of the headrest 3 is disposed so as to overlap the blower device 100 in a front view. This point will be described in more detail below with reference to FIG. Fig. 10 is a side cross-sectional view of the seat back 2 and the headrest 3. As shown in Fig. 10, the headrest 3 is attached to a bracket 46 of the seat back 2 at the upper end of the seat back 2 so as to protrude forward (toward the seat occupant) from the seating surface 2d of the seat back 2. Specifically, the headrest 3 is attached to a front surface 46a of the bracket 46 via a headrest frame 70. The lower end of the headrest 3 is arranged so as to overlap with the blower device 100 in a front view. In other words, the lower end of the headrest 3 is located below the upper end of the blower device 100.

[0063] Conventionally, the headrest 3 has been attached via a headrest peeler so as to extend above the seat back 2 as shown by the two-dot chain line in Figure 10. In this case, the load applied from the back (mainly the shoulders) of the seated occupant is supported at the back support point Pb, and the load applied from the head is supported at the head support point Ph1. Therefore, as the seat back 2 has become thinner, when the seated occupant applies a large load rearward in the direction indicated by arrow A, the load may reach the blower device 100 via the first pad material 2a and the second pad material 2b, resulting in a deterioration in the performance of the blower device 100.

[0064] In contrast, in the vehicle seat S according to this embodiment, the headrest 3 is attached to the seat back 2 so as to protrude forward (toward the seated occupant), and is positioned so that the lower end of the headrest 3 overlaps the blower device 100 in a front view. As a result, the head support point Ph2 is displaced forward (toward the seated occupant) compared to the conventional head support point Ph1, and the load applied by the seated occupant is effectively distributed to the back support point Pb and the head support point Ph2, thereby reducing the load applied to the blower device 100 compared to the conventional case. Furthermore, since the front of the blower device 100 is covered by the headrest 3, the load applied to the blower device 100 can be absorbed by the first pad material 2a and the second pad material 2b of the seat back 2 and the pad material 3a of the headrest 3. Therefore, even if the seat back 2 is made thinner, excessive load from the seated occupant is prevented from being applied to the blower device 100, thereby preventing a decrease in performance of the blower device 100.

[0065] To further explain the positional relationship between the headrest 3 and the blower device 100, the lower end of the headrest 3 is positioned so as to overlap at least one of the multiple rotary vanes 101b when viewed from the front. This allows the weight of the seated occupant to be absorbed by the first pad material 2a and second pad material 2b of the seat back 2 and the pad material 3a of the headrest 3, making it possible to prevent damage to the rotary vanes 101b, which have relatively low strength among the components of the blower device 100.

[0066] Furthermore, the lower end of the headrest 3 overlaps with the first blower device fixing portion 104a in a front view (see FIG. 9). Therefore, even if the fastening member (screw) that fixes the first blower device fixing portion 104a protrudes forward (toward the seated person), the fastening member is covered by the pad material 3a of the headrest 3, which makes it possible to prevent the occupant from feeling a foreign body sensation when seated.

[0067] The blower device 100 also has a blower connector 121 that allows insertion and removal of a connection cable 105 electrically connected to the blower device 100. The lower end of the headrest 3 is located above the blower connector 121. Therefore, the headrest 3 covers the front of the blower connector 121, preventing a decrease in workability when inspecting the blower device 100 by inserting and removing the blower cable 120. The blower cable 120 electrically connects the above-mentioned control device 90 and the blower device 100, and transmits a control signal output by the control device 90 to the blower device 100.

[0068] In addition, the lower end of the headrest frame 70 is positioned higher than the upper end of the blower device 100. This allows the highly rigid headrest frame 70 to cover the front of the blower device 100, preventing a decrease in performance of the blower device 100 due to the weight of the seated occupant's head being applied to the blower device 100 via the headrest frame 70. In Fig. 11, the position of the lower end of the headrest frame 70 in the vertical direction is indicated by L1, and the position of the upper end of the blower device 100 is indicated by L3, with L1 being positioned higher than L3.

[0069] In addition, the lower end of the headrest cover 80, which covers the rear of the headrest 3, is located above the upper end of the blower device 100. Here, the headrest cover 80 is a molded body made of synthetic resin and is not breathable. Therefore, by locating the lower end of the headrest cover 80 above the blower device 100, it is possible to suppress a decrease in air intake performance caused by the headrest cover 80 covering the intake port 102 of the blower device 100, and thereby prevent a decrease in performance of the blower device 100. In Figure 11, the position of the lower end of the headrest cover 80 in the vertical direction is indicated by L2, and the position of the upper end of the blower device 100 is indicated by L3, with L2 located above L3.

[0070] In addition, the lower end of the headrest 3 is located above the rotation axis 101a of the blower body 101. This prevents the headrest 3 from covering the front of the blower body 101, which would otherwise cause a decrease in performance of the blower device 100. In Figure 11, the position of the lower end of the headrest 3 in the up-down direction is indicated by L4.

[0071] <Method for manufacturing a vehicle seat> Next, a method for manufacturing the vehicle seat S will be described. First, the seat back module 2M is assembled. Specifically, the blower device 100 and electrical components including the electric motor 108 are attached to the first back cover 40. Next, the front of the first back cover 40 is covered with the first padding 2a, the seat heater 110, and the second padding 2b, and is then covered with the covering material 2c, thereby completing the assembly of the seat back module 2M.

[0072] Next, the headrest 3 is attached to the upper end of the seatback module 2M so as to protrude forward (toward the seat occupant) from the seating surface 2d. Specifically, the headrest 3 is attached via the headrest frame 70 to the front surface 46a of the bracket 46 that protrudes forward from the seating surface 2d of the seatback module 2M. This allows the headrest 3 to be attached to the seatback module 2M while being positioned forward (toward the seat occupant) from the seating surface 2d of the seatback module 2M.

[0073] Next, the seat back module 2M to which the headrest 3 is attached and the second back cover 50 are assembled to the seat back frame 30. Specifically, the seat back module 2M and the second back cover 50 are assembled to the module assembly portion 34 of the seat back frame 30 so as to sandwich the seat back frame 30 from the front and rear.

[0074] Similarly, the seat cushion module 1M is assembled, and then the seat cushion module 1M is attached to the seat cushion frame 10. Finally, the cables connected to the electrical components (blower connection cable 120, heater connection cable 130, etc.) are connected to the control device 90 or an on-vehicle device. In this manner, the vehicle seat S is manufactured.

[0075] Although a vehicle seat S according to one embodiment of the present invention has been described above, the above-described embodiment is merely 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 the present invention naturally includes equivalents thereof.

[0076] The vehicle seat S in the above-described embodiment has been described as having a seat cushion module 1M replaceably attached to the seat cushion frame 10, but is not limited to this. The present invention may also be applied to a vehicle seat S in which the seat cushion 1 has a seat cushion frame 10 and a cushion pad material, but does not have a replaceable seat cushion module 1M. Similarly, although the seat back module 2M is replaceably attached to the seat back frame 30 of the vehicle seat S in the above description, the present invention is not limited to this. The present invention may also be applied to a vehicle seat S in which the seat back 2 has the seat back frame 30 and a back pad material, but does not have a replaceable seat back module 2M.

[0077] In the above embodiment, the blower device 100 is described as drawing in air from the front and generating an airflow that flows downward behind the first back cover 40, but is not limited to this. The blower device 100 may also draw in air from below and generate an airflow that flows forward. Furthermore, although the blower device 100 has been described as drawing in air from the suction port 102 of the blower body 101, the present invention is not limited to this. The first pad material 2a and the second pad material 2b may have the air suction port 102 and a ventilation duct through which the drawn-in air passes, and the air may be drawn in through the ventilation duct.

[0078] In the above-described embodiment, the first back cover 40 has the first opening 44, and the second back cover 50 has the second opening 54. However, the present invention is not limited to this. The entire seat back 2 may be covered with the upholstery material 2c, and the first opening 44 or the second opening 54 may be closed.

[0079] In the above-described embodiment, a vehicle seat S mounted on a vehicle is given as an example of a vehicle seat, and an example of the configuration thereof has been described. However, the present invention is not limited to seats mounted on ground vehicles having wheels such as automobiles and trains, and may also be applied to seats mounted on aircraft, ships, and other vehicles that move on non-ground surfaces, for example. [Explanation of symbols]

[0080] S vehicle seat Front seat frame 1 seat cushion 1a First pad material 1b Second pad material 1c Skin material 1M Seat Cushion Module 2 seat backs 2a First pad material 2aa Blower coating 2b Second pad material 2c Skin material 2d seating surface 2M Seatback Module 3 Headrest 3a padding material 3b Skin material 4 Rail device 4a Lower rail 4b upper rail 4c Locking member 5 Reclining device 5a Reclining unit 5b Back rotation axis 5c spiral spring 10 Seat cushion frame 11 Side frame 12 Pan Frame 13 Rear connecting frame 14 Elastic spring (elastic member) 15 Support Plate 16 Cushion module assembly section 20 Cushion base cover 21 Cover side part 22 Front part of cover 23 Rear part of cover 24 Assembly section 25 Frame attachment / detachment part 30 Seat back frame 31 Backside Frame 32 Upper frame 33 Lower frame 34 Module assembly section 40 1st back cover 40a Cover body 40b Back reinforcement rib 40c front reinforcement rib 41 Cover side part 42 Upper part of cover 42a Flat plate part 42b Blower device housing recess 42c Upper reinforcement rib 42c1 Vertical reinforcing rib 42c2 Horizontal reinforcement rib 43 Lower part of cover 44 First Opening 45 Cover assembly part 46 Bracket 46a front 50 Second back cover 50a Cover body 51 Cover side part 52 Upper part of cover 53 Lower part of cover 54 Second Opening 55 Assembly section 60 Pressure Plate 61 Plate mounting part 70 Headrest frame 71 Frame body 72 Outer flange 73 Bracket assembly part 74 Cover assembly part 80 Headrest Cover 81 Cover body 82 Outer flange 83 Mounting opening 84 Assembly section 90 Control device 91 Bracket 100 Blower device (air flow generating device) 101 Blower body 101a Rotation axis 101b Rotating blade 102 Intake port 103 Air outlet 104 Blower device fixing part (fixing member) 104a First blower device fixing part 104b Second blower device fixing part 104c Third blower device fixing part 108 Electric Motor 110 Seat heater 120 Blower connection cable 121 Blower connector 130 Heater connection cable Phase 1: Head support point in conventional example Ph2 Head support point Pb back support point

Claims

1. A vehicle seat including a headrest and a seat back that supports the headrest, The headrest is attached to the seat back at an upper end portion of the seat back so as to protrude forward from a seating surface of the seat back, the seat back has an airflow generating device that generates an airflow below the headrest, A vehicle seat, characterized in that a lower end of the headrest overlaps with the air flow generating device in a front view.

2. the airflow generating device has a plurality of rotary blades that rotate around a rotation axis extending in the front-rear direction, 2. The vehicle seat according to claim 1, wherein a lower end of the headrest overlaps with at least one of the plurality of rotary vanes in a front view.

3. 3. The vehicle seat according to claim 2, wherein a lower end of the headrest is positioned above the rotation axis.

4. The headrest is a headrest frame that forms a skeleton of the headrest; a padding material covering the front of the headrest frame; a cover member that covers the headrest frame from behind; 2. The vehicle seat according to claim 1, wherein a lower end of the headrest frame is positioned higher than an upper end of the air flow generating device.

5. 5. The vehicle seat according to claim 4, wherein a lower end of the cover member is positioned above an upper end of the air flow generating device.

6. The seat back has a bracket that protrudes forward from the seating surface, 5. The vehicle seat according to claim 4, wherein the headrest is attached to a front surface of the bracket via the headrest frame.

7. the airflow generating device is fixed to the seat back by a fixing member that fixes the airflow generating device to the seat back, 2. The vehicle seat according to claim 1, wherein a lower end of the headrest overlaps with the fixing member in a front view.

8. the airflow generating device has a connector that allows insertion and removal of a connection cable electrically connected to the airflow generating device, 2. The vehicle seat according to claim 1, wherein a lower end of the headrest is positioned above the connector.

9. A method for manufacturing a vehicle seat including a headrest and a seat back supporting the headrest, comprising: Attaching an air flow generating device to the seat back to generate an air flow; and attaching the headrest to an upper end of the seat back so as to protrude forward from a seating surface of the seat back, The method for manufacturing a vehicle seat, wherein the air flow generating device is configured so that lower ends of the headrests overlap each other in a front view when the headrests are attached to the seat back.

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