Vehicle seat and method for manufacturing the vehicle seat

Abstract

To improve workability when installing or replacing a seat back. [Solution] The vehicle seat S is a vehicle seat S comprising a seat back 2 and a headrest 3, the seat back 2 comprising a seat back frame 30 and a seat back module 2M provided in front of the seat back frame, and the headrest 3 attached to the seat back module 2M. This improves the workability when installing or replacing the seat back 2.

Description

[Technical Field]

[0001] The present invention relates to a vehicle seat and a method for manufacturing a vehicle seat, and more particularly to a vehicle seat provided with a headrest and a method for manufacturing a vehicle seat. [Background technology]

[0002] Patent Document 1 discloses a method for assembling a seat back assembly in which a pre-assembled front seat back module and a rear seat back module are interconnected around a seat back frame. In the method for assembling a seat back assembly in Patent Document 1, after the front seat cushion module and the rear seat back module are joined to the seat cushion frame, a headrest is joined to the top of the seat back assembly. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] US Patent No. 10046682 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the vehicle seat assembly described in Patent Document 1, the headrest is attached to the seatback frame after the front seat cushion module and the rear seatback module are joined together. Therefore, for example, when replacing the front seat cushion module with another module, the headrest must be removed from the seatback frame once, which reduces workability.

[0005] The present invention has been made in consideration of the above-mentioned problems, and its object is to provide a vehicle seat and a method for manufacturing a vehicle seat that improves workability when installing or replacing a seat back. [Means for solving the problem]

[0006] The above problem is solved by the vehicle seat of the present invention, which is a vehicle seat comprising a seat back and a headrest, wherein the seat back comprises a seat back frame and a seat back module provided in front of the seat back frame, and the headrest is attached to the seat back module. The above configuration makes it possible to replace the seat back module without removing the headrest, thereby improving the workability when installing or replacing the seat back compared to, for example, when the headrest is attached to the seat back frame.

[0007] Furthermore, the above problem is solved by the method for manufacturing a vehicle seat of the present invention, which is a method for manufacturing a vehicle seat comprising a seat back frame, a seat back module provided in front of the seat back frame, a rear back cover provided behind the seat back frame, and a headrest attached to the seat back module, and includes attaching the headrest to the seat back module, and attaching the seat back module with the headrest attached to the seat back frame. The above configuration makes it possible to replace the seat back module without removing the headrest, thereby improving the workability when installing or replacing the seat back compared to, for example, when the headrest is attached to the seat back frame.

[0008] In the above configuration, the headrest has a headrest frame that forms the skeleton of the headrest, and an attachment bracket for fixing the headrest frame is provided on the upper portion of the seatback module, and a through hole is formed behind the attachment bracket, and the headrest frame is fixed to the attachment bracket by a fastening member, and the fastening member is positioned in a position that overlaps with the through hole in the fore-and-aft direction. With the above configuration, the headrest can be attached to the seat back module by inserting the fastening member from behind the seat back module.

[0009] In the above configuration, it is preferable that a rear back cover be provided behind the seat back frame, and the through hole formed in the seat back module be covered from behind by the rear back cover. With the above-described configuration, the fastening members and mounting brackets for attaching the headrest can be hidden.

[0010] In the above configuration, the through hole of the seat back module may be provided above the seat back frame. With the above configuration, the fastening member can be easily seen through the through hole even after the seat back module is attached to the seat back frame.

[0011] In the above configuration, the seat back module may have an engagement portion below the through hole that engages with the seat back frame. With the above configuration, for example, the seat back module can be easily attached to the seat back frame even after the headrest has been attached.

[0012] In the above configuration, the headrest may include a headrest cover provided behind the headrest frame, the mounting bracket may have a protruding portion that protrudes forward, and the headrest cover may have a mounting opening through which the protruding portion of the mounting bracket is inserted. With the above configuration, the headrest can be attached more firmly to the seat back module.

[0013] In the above configuration, the seatback frame has side frames arranged on both sides and an upper frame connecting the upper ends of the side frames, the seatback module has a front back cover attached to the seatback frame, the front back cover has an engaging portion that engages with the upper frame and a connecting piece that protrudes rearward and connects to the side frame, and the side frame is provided with a fixing portion that fixes the connecting piece. With the above configuration, the seat back module can be easily attached to the seat back frame.

[0014] In the above configuration, the connecting piece is insert-molded into the front back cover, and the connecting piece is composed of a base portion that is placed inside the front back cover and an attachment portion that extends rearward from the side of the base portion and is attached to the side frame, and it is preferable that the base portion be larger than the attachment portion. With the above-described configuration, the connecting piece can be more firmly fixed to the front back cover.

[0015] In the above configuration, the seatback frame has side frames arranged on both sides and an upper frame connecting the upper ends of the side frames, the seatback module has a front back cover attached to the seatback frame, the front back cover has connecting pieces that protrude rearward and connect to the side frames, and the connecting pieces are preferably positioned below the lower ends of the upper frames. With the above configuration, it is possible to prevent the connecting piece from interfering with the upper frame when assembling the seat back module to the back frame.

[0016] In the above configuration, the seatback frame has side frames arranged on both sides and an upper frame connecting the upper ends of the side frames, and the upper frame is composed of a horizontal frame extending in the seat width direction and a vertical frame extending downward from both ends of the horizontal frame, and the seatback module has a front back cover attached to the seatback frame, and the front back cover has a guide piece that protrudes rearward and abuts against the inside of the vertical frame, and a fixing piece that protrudes rearward and fixes the vertical frame from the outside, and the vertical frame is sandwiched between the guide piece and the fixing piece. With the above configuration, when the seat back module is assembled to the seat back frame, the seat back module can be guided to an appropriate position.

[0017] In the above configuration, a rib is formed on the rear surface of the front back cover, and a recess is formed in the portion of the rib that abuts against the vertical frame of the upper frame, the recess matching the outer shape of the vertical frame. With the above-described configuration, when the seat back module is assembled to the seat back frame, the seat back module can be guided to an appropriate position, and movement of the vertical frame in the seat width direction can be suppressed. [Effects of the Invention]

[0018] According to the vehicle seat of the present invention, it is possible to replace the seat back module without removing the headrest, thereby improving the workability when installing or replacing the seat back compared to, for example, when the headrest is attached to the seat back frame. Furthermore, according to the manufacturing method of the vehicle seat of the present invention, the headrest can be attached to the seat back frame in an attached state without being removed, which improves the workability when installing or replacing the seat back compared to, for example, when the headrest is attached to the seat back frame. Furthermore, according to the present invention, the headrest can be attached to the seat back module by inserting the fastening member from behind the seat back module. Furthermore, according to the present invention, the fastening members and mounting brackets for mounting the headrest can be hidden. Furthermore, according to the present invention, even after the seat back module is attached to the seat back frame, the fastening members can be easily seen through the through holes. Furthermore, according to the present invention, the seat back module can be easily attached to the seat back frame, even after the headrest has been attached, for example. Furthermore, according to the present invention, the headrest can be attached to the seat back module more firmly. Furthermore, according to the present invention, the seat back module can be easily attached to the seat back frame. Furthermore, according to the present invention, the connecting piece can be more firmly fixed to the front back cover. Furthermore, according to the present invention, when the seat back module is attached to the back frame, interference between the connecting piece and the upper frame can be suppressed. Furthermore, according to the present invention, when the seat back module is assembled to the seat back frame, the seat back module can be guided to an appropriate position, and movement of the vertical frame in the seat width direction can be suppressed. [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 perspective view of the vehicle seat as seen from diagonally rearward. [Figure 3] FIG. [Figure 4] FIG. [Figure 5] FIG. 2 is an exploded perspective view of the seat back module. [Figure 6]FIG. [Figure 7] FIG. 2 is a perspective view of the seat back module as seen from diagonally rearward. [Figure 8] FIG. 2 is a rear view of the seat back module as seen from the rear. [Figure 9] FIG. 2 is a front view of the first back cover as seen from the front. [Figure 10] 9 is a cross-sectional view of the upper part of the seat back taken along line XX in FIG. 8. [Figure 11] FIG. 2 is a partially enlarged perspective view showing the periphery of a back side frame. [Figure 12] 12 is a cross-sectional view taken along line XII-XII in FIG. 8, and shows mainly the connecting piece. [Figure 13] FIG. 2 is a side view of a back side frame to which a seat back module is attached. [Figure 14] FIG. 2 is an enlarged perspective view of a portion of the seat back module. [Figure 15] FIG. 2 is a flow chart showing a method for manufacturing a vehicle seat. DETAILED DESCRIPTION OF THE INVENTION

[0020] 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, a vehicle seat S mounted on a ground vehicle having wheels, such as an automobile or train, will be taken as an example of a vehicle seat, and an example of its configuration will be described. 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 traveling direction when the vehicle is traveling. 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. Furthermore, unless otherwise specified, the shape, position, and posture of each part of the vehicle seat S described below will be described assuming that the vehicle seat S is in an occupant's seated position.

[0022] <Vehicle seat S> The basic configuration of a vehicle seat S according to this embodiment will be described with reference to Figs. 1 to 6. Fig. 1 is a perspective view of the vehicle seat S as seen obliquely from the front, and Fig. 2 is a perspective view of the vehicle seat S as seen obliquely from the rear. Fig. 3 is an exploded perspective view of the seat cushion 1, and Fig. 4 is an exploded perspective view of the seat back 2. Fig. 5 is an exploded perspective view of the seat back module 2M. Fig. 6 is an exploded perspective view of the headrest 3. Note that in Fig. 1, for convenience of illustration, parts of the vehicle seat S are shown with the upholstery materials 1c, 2c, and 3b removed.

[0023] 1 and 2, the vehicle seat S according to this embodiment mainly comprises a seat cushion 1, a seat back 2, a headrest 3, a rail device 4, and a reclining device 5. A seat frame F that forms the framework of the seat cushion 1 and the seat back 2 is provided inside the seat cushion 1 and the seat back 2. The seat cushion frame includes a seat cushion frame 10, a seat back frame 30, and a headrest frame 70, which will be described later.

[0024] <Seat cushion 1> The seat cushion 1 is a support member that supports the buttocks of a seated occupant (hereinafter, sometimes referred to as a seated person), and supports the seated person from below. As shown in Fig. 3, the seat cushion 1 mainly comprises a seat cushion frame 10 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 that is 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 pressure-receiving member that receives the load of a seated occupant applied via a seat cushion module 1M (described later), and is elastic and configured to bend downward.

[0026] Cushion module assembly portions 16 are provided on both sides of the pan frame 12 in the seat width direction. 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 (described later). This makes it possible to assemble the seat cushion module 1M to the seat cushion frame 10 in a replaceable manner.

[0027] <Seat cushion module 1M> The seat cushion module 1M mainly comprises a cushion base cover 20, a first padding material 1a, a second padding material 1b, and a covering material 1c. The seat cushion module 1M is attached to a seat cushion frame 10 to function as a seat portion of the vehicle seat S. The seat cushion module 1M is also removable and replaceable, and by replacing it, the design and function of the vehicle seat S can be changed. Therefore, the vehicle seat S can be configured to be optimal according to the needs of each seat occupant.

[0028] 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. 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 fixing the assembly portion 24 to the pan frame 12. In this embodiment, the cushion base cover 20 is made of resin. The cushion base cover 20 may also be made of metal.

[0029] A control device 90 is attached below the cushion base cover 20 via a bracket 91. The control device 90 is called an ECU (Electronic Control Unit) and controls various sensors and electrical components mounted on the vehicle or the vehicle seat S. For example, the control device 90 acquires an output signal from a detection sensor (such as a temperature sensor) mounted on the vehicle, and controls a blower device 100 and a seat heater 110 (described later) based on the output signal, thereby improving the comfort of the occupant seated in the vehicle seat S.

[0030] The first pad material 1a and the second pad material 1b are cushion materials 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 made of foamed resin molded bodies having different properties (breathability and flexibility). By stacking multiple foamed resin molded bodies having different properties, it is possible to improve seating comfort and comfort while reducing manufacturing costs and the thickness of the cushion base cover 20, for example. The first pad material 1a placed on the cushion base cover 20 is made of a three-dimensional network fiber structure such as BreathAir (registered trademark). The second pad material 1b is made of a urethane resin (foamed resin) such as soft polyurethane foam. The second pad material 1b may also be made of biomass urethane.

[0031] The second padding 1b is placed on top of the first padding 1a after it has been placed on the cushion base cover 20. The second padding 1b is covered with a skin 1c. The skin 1c is made of, for example, a stretchable synthetic leather material. The skin 1c may also be made of cloth, film, leather, or the like.

[0032] <Seatback 2> The seat back 2 is a support member that supports the back of a seated occupant from behind. As shown in Fig. 4, the seat back 2 has a seat back frame 30 that forms the framework of the seat back 2, a seat back module 2M that is replaceably attached to the seat back frame 30 from the front of the seat back frame 30, and a second back cover 50 that covers the seat back 2 from the rear.

[0033] The seatback frame 30 is a frame body having a generally rectangular shape when viewed from the front. The seatback frame 30 has backside frames 31 arranged on both sides of the seatback frame 30, i.e., on the left and right, 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. The backside frames 31 correspond to the side frames of the present invention.

[0034] 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 bar formed by bending a plate-like member vertically. The front edges of the backside frames 31 are bent outward to improve their strength. A reclining body 5a, a back rotation shaft 5b, and a spiral spring 5c ​​of the reclining device 5, which will be described later, are attached to the lower end of the back side frame 31.

[0035] The upper frame 32 is a frame material 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 metal round pipe material. The upper frame 32 may also be made of resin. The upper frame 32 is provided with four module assembly parts 34 arranged at substantially equal intervals from one another. The module assembly parts 34 protrude outward from the upper frame 32, and are assembled to a cover assembly part 45 provided on the first back cover 40 and an assembly part 55 provided on the second back cover 50 by being connected and fixed thereto. The upper frame 32 is composed of a horizontal frame 32a extending in the seat width direction and vertical frames 32b extending downward from both ends of the horizontal frame 32a.

[0036] The lower frame 33 is a long frame member extending laterally, and connects 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 member 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.

[0037] <Seatback Module 2M> 5, the seatback module 2M mainly comprises a first back cover 40, a pressure-receiving plate 60, a first padding material 2a, a second padding material 2b, a seat heater 110, and an upholstery material 2c. As described above, the seatback module 2M is attached to the seatback frame 30 to function as the backrest of the vehicle seat S. By removing and replacing the seatback module 2M, the design and function of the vehicle seat S can be easily changed, and an optimal vehicle seat S can be configured to meet the needs of each individual seated occupant.

[0038] The first back cover 40 is a cover member that supports electrical components provided in the seat back module 2M and protects the electrical components by covering them from the rear. The first back cover 40 corresponds to the front back cover of the present invention. Examples of electrical components provided in the seat back module 2M include a blower device 100, an electric motor 108, and a seat heater 110. Although not shown, an air cell or an airbag device may also be provided.

[0039] The first back cover 40 has a resin cover body 40a, and a first opening 44 is formed in the approximate center of the cover body 40a (see FIG. 9). 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.

[0040] A pressure-receiving plate 60 that receives the load of a seated occupant is provided on the front side of the first back cover 40. The pressure-receiving plate 60 is provided so as to cover the first opening 44 formed in the cover main body 40a. In other words, the first opening 44 formed in the cover main body 40a is formed in a position facing the pressure-receiving plate 60. Therefore, when the load 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.

[0041] The cover body 40a has left and right cover side portions 41 on the outer sides in the seat width direction of the first opening 44. The cover body 40a also has an upper cover portion 42 above the first opening 44 and a lower cover portion 43 below it.

[0042] 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 the back side of the cover side portion 41, which is located on the right side when viewed from the front, and is supported by the cover side portion 41.

[0043] <Bracket 46> As shown in FIG. 5, the cover upper portion 42 has an upwardly protruding mountain-like shape, and its end in the seat width direction connects the upper ends of the left and right cover side portions 41. A bracket 46 to which the headrest 3 is attached is provided at the upper end of the cover upper portion 42. The bracket 46 corresponds to the mounting bracket of the present invention. The bracket 46 has a protruding portion 46c that protrudes forward from the cover upper portion 42, and is configured to fix the headrest 3 at the upper end of the seat back 2 in a state where it protrudes forward from the seating surface 2d of the seat back 2 (see FIG. 10). In addition, a front surface 46a of the bracket 46 abuts against the bracket assembly portion 73. A through-hole for passing a fastener 75 is formed in the front surface 46a.

[0044] Furthermore, a bracket through-hole 46b is formed at the rear of the bracket 46 (see FIG. 8). For example, a bolt of a fastener 75 (fastening member) inserted from the headrest side can be tightened through the bracket through-hole 46b. That is, the headrest frame 70 of the headrest 3 is fastened and fixed by the bracket 46 and the fastener 75, and the fastener 75 is disposed at a position overlapping with the bracket through-hole 46b in the front-rear direction.

[0045] By forming the bracket through-hole 46b in this manner, a fastener 75 can be inserted from the rear of the seat back module 2M to attach the headrest 3 to the seat back module 2M. The bracket through-hole 46b is configured to be covered from the rear by the second back cover 50 (rear back cover) when the seat back module 2M and the second back cover 50 are assembled, thereby making it possible to hide the fastener 75 and bracket 46 that attach the headrest.

[0046] Furthermore, the bracket through-holes 46b are provided above the seatback frame 30 (see FIG. 8). By providing the bracket through-holes 46b, the fasteners 75 can be easily seen through the bracket through-holes 46b even after the seatback module 2M is attached to the seatback frame 30.

[0047] 5, a blower device 100 that generates an air flow is attached near the center of the cover upper portion 42. The seat back module 2M is configured so that the blower device 100 draws air from the seating surface 2d side of the seat back 2 (from the front of the seat) and blows the air downward at the back side of the seat back 2.

[0048] The cover lower portion 43 extends in the seat width direction, and its ends in the seat width direction connect the lower ends of the left and right cover side portions 41. 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.

[0049] The first padding material 2a and the second padding material 2b are cushioning materials placed on the first back cover 40 to cover the first back cover 40. The first padding material 2a and the second padding material 2b are foamed resin molded bodies having different properties (breathability and flexibility). In this embodiment, the first padding material 2a is configured to have higher breathability than the second padding material 2b, and the second padding material 2b is configured to have higher flexibility than the first padding material 2a. The first padding material 2a is made of a three-dimensional network fiber structure such as BreathAir (registered trademark). The second padding material 2b is made of a urethane resin (foamed resin) such as soft polyurethane foam. The second padding material 2b may also be made of biomass urethane.

[0050] After the first padding material 2a is placed on the first back cover 40, the second padding material 2b is attached to the first back cover 40 with the seat heater 110 sandwiched therebetween. The second padding 2b is covered with a skin 2c, which may be made of a stretchable synthetic leather material, or may be made of cloth, film, leather, or the like.

[0051] The first pad material 2a is formed with a blower covering portion 2aa facing the blower device 100, and an empty space capable of supplying air to an area facing the suction port 102 of the blower device 100 is provided. The first padding 2a and the second padding 2b are laminated together and covered with a skin 2c, which may be made of a stretchable synthetic leather material, or may be made of cloth, film, leather, or the like.

[0052] <Second back cover 50> The second back cover 50 will be described with reference to FIG. 4. The second back cover 50 is disposed behind the seat back frame 30 and attached so as to cover the entire seat back frame 30 from behind. The second back cover 50 corresponds to the rear back cover of the present invention. The second back cover 50 is a cover member made of resin. The seat back 2 is completed when the second back cover 50 and the seat back module 2M are fixed together while sandwiching the seat back frame 30 from the front-rear direction. The second back cover 50 may be made of metal.

[0053] The second back cover 50 has a cover body 50a, and a second opening 54 is 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 also 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. A plurality of ribs may also be provided inside the cover body 50a.

[0054] 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. In other words, when the pressure plate 60 is deformed rearward, the deformed portion passes through the inside of the first opening 44 and the second opening 54, so the deformation is not obstructed, and the occupant is prevented from feeling the pressure plate 60 bottom out.

[0055] 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.

[0056] <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.

[0057] Furthermore, the headrest 3 is attached to the seatback module 2M. This makes it possible to replace the seatback module 2M without removing the headrest 3. Conventionally, the headrest 3 was attached to the seatback frame 30, but replacing the seatback module required removing the headrest 3 first. By providing the headrest 3 in the seatback module 2M, it is no longer necessary to remove the headrest 3, improving the workability when replacing the seatback. In other words, the seatback module 2M can be replaced together with the headrest 3, improving the workability when replacing the seatback.

[0058] The headrest frame 70 is a plate-like member 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 portion 73 that is attached to the bracket 46 of the seat back module 2M is provided in the center of the frame main body 71, and is fixed to the bracket 46 by inserting a fastener 75 into a through-hole formed in the bracket assembly portion 73.

[0059] 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.

[0060] 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. In other words, the headrest 3 has the headrest cover 80 provided behind the headrest frame 70. The headrest cover 80 has approximately the same outer dimensions as the headrest frame 70, and has 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.

[0061] An attachment opening 83 is formed in the approximate center of the headrest cover 80, allowing the bracket 46 to pass through. When the protrusion 46c of the bracket 46 passes through the attachment opening 83, the bracket 46 and the bracket assembly portion 73 of the headrest frame 70 are connected, and the headrest 3 can be attached to the first back cover 40 of the seat back module 2M. By configuring the headrest 3 in this way, the headrest 3 can be attached more firmly to the seat back module 2M.

[0062] Additionally, at the four corners (upper right, upper left, lower right, and lower left) of the headrest cover 80, there are provided assembly portions 84 for assembling the headrest cover 80 to the headrest frame 70. The assembly portions 84 protrude forward and can be engaged with the cover assembly portions 74 of the headrest 3.

[0063] The padding 3a is a cushioning material that covers the front of the headrest frame 70. The padding 3a is made of a foamed resin molded body. More specifically, the padding 3a is made of a urethane resin such as soft polyurethane foam. The padding 3a may also be made of biomass urethane. The skin material 3b is made of a stretchable synthetic leather material and covers the padding 3a.

[0064] <Rail device 4> As shown in Fig. 1, the rail device 4 is a device that connects the vehicle seat S to the floor of the vehicle so that the seat can slide in the front-to-rear direction. As shown in Fig. 1, the rail device 4 is provided below the vehicle seat S. 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-to-rear direction relative to the lower rail 4a.

[0065] 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.

[0066] <Reclining device 5> The reclining device 5 has a reclining main body 5a, a back rotation shaft 5b, and a spiral spring 5c, and connects the seat back 2 to the seat cushion 1 so that the seat back 2 can rotate about the back rotation shaft 5b. As shown in FIG. 4, the reclining device 5 is provided below the seat back frame 30. The reclining device 5 can displace the seat back 2 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 rearward-tilted position in which the seat back 2 is tilted backward.

[0067] <Blower device 100> As shown in Fig. 5, 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 below the blower body 101 and having an opening on the left side. In other words, by rotating the blower body 101, the blower device 100 draws air from the front (from the seating surface 2d toward the inlet 102) and generates an airflow that flows downward (from the cover upper portion 42 toward the first opening 44). This allows, for example, air around a seated person to be drawn in from the seating surface 2d and discharged downward from the vehicle seat S, thereby improving the comfort of the occupant sitting in the vehicle seat S. In addition, a blower connection cable 120 extends from the blower device 100 and is connected to the control device 90.

[0068] <Cover mounting part 49> The cover mounting portion 49 for mounting the seat back module 2M to the seat back frame 30 will be described below with reference to the drawings. 7, a plurality of cover attachment portions 49 are provided on the back surface side (rear surface side) of the first back cover 40 constituting the seat back module 2M. Each cover attachment portion 49 is composed of an engagement portion 49a, a connecting piece 49b, a fixing piece 49c, and a guide piece 49d.

[0069] As shown in Fig. 7, the engaging portion 49a is provided on the cover upper portion 42 and is arranged below the bracket through-hole 46b. The engaging portion 49a is formed in a hook shape so as to hook onto the horizontal frame 32a of the upper frame 32 (see Figs. 7 and 13). When attaching the seat back module 2M to the seat back frame 30, the worker first hooks the engaging portion 49a onto the horizontal frame 32a, and then rotates it downward to attach the other cover attaching portion 49 to the seat back frame 30.

[0070] As shown in Fig. 7, the connecting piece 49b is provided on the lower portion of the cover side portion 41. As shown in Fig. 12, the connecting piece 49b is a member with an L-shaped cross section formed by bending a plate-like member, and is composed of an attachment portion 49ba and a base portion 49bb. The attachment portion 49ba extends rearward from the side portion of the base portion 49bb and is configured to be attached to the back side frame 31. The base portion 49bb is inserted into the first back cover 40.

[0071] The length L2 of the base portion 49bb is longer than the length L1 of the attachment portion 49ba. That is, the surface area of ​​the base portion 49bb is larger than the surface area of ​​the attachment portion 49ba. This allows the joining piece 49b to be fixed to the first back cover 40 more firmly.

[0072] 11, when the seatback module 2M is attached to the seatback frame 30, the connecting piece 49b overlaps the side of the backside frame 31 and can be fastened to a fixing portion provided on the backside frame 31 by a fastener 49bd. More specifically, a through-hole 49bc into which the fastener 49g is inserted is configured to overlap with a fixing portion of the backside frame 31. In this way, by providing the connecting piece 49b, the seat back module 2M can be easily attached to the seat back frame 30.

[0073] 13, when the seatback module 2M is attached to the seatback frame 30, the connecting piece 49b is preferably located below the lower end 32ba of the upper frame 32. By arranging the connecting piece 49b in this manner, it is possible to prevent the connecting piece 49b from interfering with the upper frame 32 when the seatback module 2M is attached to the seatback frame 30.

[0074] As shown in FIG. 7, the fixing piece 49c and the guide piece 49d are provided on the upper portion of the cover side portion 41. The fixing piece 49c and the guide piece 49d are formed to protrude rearward from the rear surface of the first back cover 40. As shown in FIG. 14, the fixing piece 49c fixes the vertical frame 32b from the outside via a fixing member 49f. The guide piece 49d abuts against the inside of the vertical frame 32b. The vertical frame 32b is sandwiched and fixed between the fixing piece 49c and the guide piece 49d. By providing the fixing piece 49c and the guide piece 49d in this manner, the seat back module 2M can be guided and fixed to an appropriate position when assembling the seat back module 2M to the seat back frame 30.

[0075] 7 and 14, a plurality of rear reinforcement ribs 41a (ribs) are formed on the rear surface of the cover side portion 41 of the first back cover 40. The rear reinforcement rib 41a is part of the rear reinforcement rib 40b of the cover main body 40a. The rear reinforcement rib 41a is provided with recesses 49e formed to match the outer shape of the vertical frames 32b of the upper frame 32 at the portions where it abuts against the vertical frames 32b. When the seatback module 2M is attached to the seatback frame 30, the vertical frames 32b fit into the recesses 49e, thereby preventing misalignment in the seat width direction. Furthermore, when the seatback module 2M is fixed by the fixing members 49f, lateral movement of the seatback frame 30 is prevented.

[0076] <Method for manufacturing vehicle seat S> A method for manufacturing the vehicle seat S, particularly the method for manufacturing the seat back 2, will be described with reference to the flow chart shown in FIG. First, prepare the components that make up the seat back frame 30, the seat back module 2M, the second back cover 50, and the headrest 3. At this time, it is preferable that the seat back frame 30 is assembled to the completed seat cushion 1.

[0077] Next, the seat back module 2M is assembled. Specifically, the pressure-receiving plate 60, the first pad material 2a, the second pad material 2b, etc. are attached to the first back cover 40 (step S101).

[0078] Next, the headrest 3 is assembled. Specifically, the headrest cover 80, the padding material 3a and the covering material 3b of the headrest 3 are attached to the headrest frame 70 (step S102). Next, the assembled headrest 3 is attached to the seat back module 2M. Specifically, the bracket 46 of the seat back module 2M is inserted into the attachment opening 83 of the headrest cover 80 and fastened and fixed with the fastener 75 (step S103).

[0079] Next, the seat back module 2M is attached to the seat back frame 30, and the second back cover 50 is assembled to the seat back module 2M and the seat back frame 30 from behind the seat (step S104). When attaching the seat back module 2M to the seat back frame 30, the engagement portion 49a is hooked onto the lateral frame 32a, and then the seat back module 2M is rotated to fix the connecting piece 49b to the back side frame 31. In this way, the vehicle seat S is completed.

[0080] When replacing the seat back module 2M, the second back cover 50 is removed from the seat back frame 30, and then the seat back module 2M is removed from the seat back frame 30 together with the headrest 3. Thereafter, another seat back module 2M with the headrest 3 attached thereto is attached to the seat back frame 30, and after being fixed to the seat back frame 30, the second back cover 50 is attached.

[0081] The seat back module 2M provided with the headrest 3 can be replaced without attaching or detaching the headrest 3 to or from the seat back frame 30, improving workability when attaching or replacing the seat back 2.

[0082] As an embodiment of the present invention, a vehicle seat S to be installed in a vehicle has been described above, and its configuration example and manufacturing method have been explained using the drawings. However, the present invention is not limited to seats installed in ground vehicles having wheels such as automobiles and trains, and may also be applied to seats installed in aircraft, ships, and other vehicles that move on non-ground surfaces, for example. [Explanation of symbols]

[0083] 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 32a horizontal frame 32b vertical frame 32ba bottom end 33 Lower frame 34 Module assembly section 40 First back cover (front back cover) 40a Cover body 40b Back reinforcement rib 40c front reinforcement rib 41 Cover side part 41a Back reinforcement rib 42 Upper part of cover 43 Lower part of cover 44 1st opening (front opening) 45 Cover assembly part 46 Bracket (mounting bracket) 46a Front part 46b Bracket through hole 46c protrusion 49 Cover mounting part 49a Engagement part 49b Connecting piece 49ba mounting part 49bb base 49c Fixed piece 49d Guide 49e Recess 49f Fixing member 49g fastener 50 Second back cover (rear back cover) 50a Cover body 51 Cover side part 52 Upper part of cover 53 Lower part of cover 54 Second opening (rear opening) 55 Assembly section 60 Pressure plate (pressure receiving member) 61 Plate mounting part 70 Headrest frame 71 Frame body 72 Outer flange 73 Bracket assembly part 74 Cover assembly part 75 Fasteners (fastening members) 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 102 Intake port 103 Air outlet 108 Electric Motor 110 Seat heater 120 Blower connection cable

Claims

1. A vehicle seat having a seat back and a headrest, The seat back is A seat back frame, a seat back module provided in front of the seat back frame, The vehicle seat is characterized in that the headrest is attached to the seat back module.

2. The headrest has a headrest frame that forms a skeleton of the headrest, an upper portion of the seat back module is provided with a mounting bracket for fixing the headrest frame, and a through hole is formed behind the mounting bracket; The headrest frame is fixed to the mounting bracket by a fastening member, The vehicle seat according to claim 1, wherein the fastening member is disposed at a position overlapping the through hole in the front-rear direction.

3. a rear back cover provided behind the seat back frame, 3. The vehicle seat according to claim 2, wherein the through-hole formed in the seat back module is covered from behind by the rear back cover.

4. 3. The vehicle seat according to claim 2, wherein the through-hole of the seat back module is provided above the seat back frame.

5. 3. The vehicle seat according to claim 2, wherein the seat back module has an engaging portion below the through hole that engages with the seat back frame.

6. The headrest includes a headrest cover provided behind the headrest frame, The mounting bracket has a protrusion that protrudes forward, 3. The vehicle seat according to claim 2, wherein the headrest cover is formed with a mounting opening through which the protrusion of the mounting bracket is inserted.

7. The seat back frame has side frames disposed on both sides and an upper frame connecting upper ends of the side frames, the seat back module has a front back cover attached to the seat back frame; the front back cover has an engaging portion that engages with the upper frame and a connecting piece that protrudes rearward and connects to the side frame, 2. The vehicle seat according to claim 1, wherein the side frame is provided with a fixing portion for fixing the connecting piece.

8. the connecting piece is insert-molded into the front back cover; the connecting piece is composed of a base portion disposed within the front back cover and an attachment portion extending rearward from a side portion of the base portion and attached to the side frame, 8. The vehicle seat according to claim 7, wherein the base portion is larger than the mounting portion.

9. The seat back frame has side frames disposed on both sides and an upper frame connecting upper ends of the side frames, the seat back module has a front back cover attached to the seat back frame; the front back cover has a connecting piece that protrudes rearward and connects to the side frame, 2. The vehicle seat according to claim 1, wherein the connecting piece is positioned below a lower end of the upper frame.

10. The seat back frame has side frames disposed on both sides and an upper frame connecting upper ends of the side frames, The upper frame is composed of a horizontal frame extending in the seat width direction and a vertical frame extending downward from both end portions of the horizontal frame, the seat back module has a front back cover attached to the seat back frame; the front back cover has a guide piece that protrudes rearward and abuts against the inside of the vertical frame, and a fixing piece that protrudes rearward and fixes the vertical frame from the outside, 2. The vehicle seat according to claim 1, wherein the vertical frame is sandwiched between the guide piece and the fixed piece.

11. A rib is formed on the rear surface of the front back cover, 11. The vehicle seat according to claim 10, wherein the rib has a recess formed in a portion of the upper frame that abuts against the vertical frame, the recess conforming to an outer shape of the vertical frame.

12. A method for manufacturing a vehicle seat including a seat back frame, a seat back module provided in front of the seat back frame, a rear back cover provided behind the seat back frame, and a headrest attached to the seat back module, attaching the headrest to the seat back module; and attaching the seat back module, to which the headrest is attached, to the seat back frame.

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