Seat backs and vehicle seats

Abstract

There is a problem in that it becomes difficult to insert a hand from the side between the front of the seat back and the top of the seat cushion when the seat back is in a horizontal position, making it difficult to raise the seat back. This invention discloses a technology that solves this problem. [Solution] The seat back of the present disclosure is a foldable seat back that folds toward the seat cushion, comprising a cushion member and a cover member that covers a part of the front side of the cushion member and is harder than the seat cushion, wherein the cover member is integrally molded with the cushion member.

Description

Technical Field

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[0001] The present disclosure relates to a seat back that is rotatably supported with respect to a seat cushion and a vehicle seat including the seat back.

Background Art

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0017] , FIG. 4)

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, the above-described conventional seat back has a problem that when it is in a horizontal position, it becomes difficult to insert a hand from the side between the seat back and the seat cushion, and it becomes difficult to raise the seat back. The present application discloses a technique for solving this problem.

Means for Solving the Problems

[0005] One aspect of the invention is a collapsible seat back that collapses toward the seat cushion, including a cushion member and a cover member that covers a part of the front side portion of the cushion member and is harder than the seat cushion, and the cover member is integrally formed with the cushion member.

Effects of the Invention

[0006] In one aspect of the invention, a portion of the front side of the seatback cushion is covered with a cover member that is harder than the seat cushion. As a result, even when the seatback is tilted to a horizontal position, neither the seat cushion nor the seatback will dig into the other in the area where the cover member is placed. Furthermore, it becomes easy to insert a finger between the seatback and the seat cushion along the front of the cover member, making it easier to raise the seatback. [Brief explanation of the drawing]

[0007] [Figure 1] Figure 1 is a perspective view of a vehicle seat according to the first embodiment. [Figure 2] Figure 2 is a perspective view of the cover member integrally molded with the cushion member. [Figure 3] Figure 3 is a side view of a vehicle seat positioned horizontally. [Figure 4] Figure 4 is a front view of the cushioning member. [Figure 5] Figure 5 is a perspective view of the cover member. [Figure 6] Figure 6A is a side cross-sectional view of a foam molding die into which foaming material has been injected, and Figure 6B is a side cross-sectional view of a foam molding die into which a cushioning material has been formed inside the cavity. [Figure 7] Figures 7A, 7B, and 7C are perspective views of cover members according to other embodiments. [Figure 8] Figure 8A is a cross-sectional view of a conventional vehicle seat, and Figure 8B is a cross-sectional view of a vehicle seat according to the first embodiment. [Figure 9] Figure 9 is a perspective view of a cover member according to another embodiment. [Modes for carrying out the invention]

[0008] [First Embodiment] Referring to Figures 1 to 6, a vehicle seat 100 according to one embodiment of the present disclosure will be described. The vehicle seat 100 of this embodiment shown in Figure 1 comprises, for example, a pair of seat backs 10, a simple seat back 102 that also serves as an armrest and is sandwiched between them, and a seat cushion 101 to which each seat back 10 and the simple seat back 102 are commonly rotatably assembled. The simple seat back 102 is connected to one of the seat backs 10 by a connecting mechanism (not shown), and normally the simple seat back 102 rotates together with one of the seat backs 10. When the connection by the connecting mechanism is released, only the simple seat back 102 can be rotated forward.

[0009] Hereafter, when the seat back 10 and the simplified seat back 102 are not distinguished, they will be referred to as "seat back 10, 102". Also, in the seat backs 10, 102 and the seat cushion 101, the side of the seat back 10, 102 closer to the center of rotation will be referred to as the "base end side", "base end", etc., and the side further away will be referred to as the "tip side", "tip", etc. Furthermore, of the seat backs 10, 102, the side facing the seated person will be referred to as the "front side", "front", etc., and the opposite side will be referred to as the "rear side", "rear surface", etc.

[0010] The vehicle seat 100 is used, for example, as a rear seat of a vehicle, with the seatbacks 10 and 102 aligned in the width direction of the vehicle and assembled to the vehicle body so that the occupant faces the direction of travel. The seatbacks 10 and 102 are foldable seatbacks, and can be folded down toward the seat cushion 100 to a position where the rear surface is approximately flat and the rear surface is approximately horizontal (hereinafter referred to as the "horizontal position") (see Figure 3). This makes it possible to make the upper surface of the luggage compartment and the rear surface of the horizontally positioned seatbacks 10 and 102 approximately flush in vehicles equipped with a luggage compartment behind the vehicle seat 100. Furthermore, in a three-row vehicle where the rear two rows are vehicle seats 100, it makes it possible to make the rear surfaces of the horizontally positioned seatbacks 10 and 102 of the rear two rows approximately flush with each other.

[0011] The side portion of the seatback 10 located on the outside in the vehicle width direction (hereinafter referred to as the "outward-facing side portion 13") faces outwards through the vehicle's entrance / exit when it is in a horizontal position. This allows a person standing outside the entrance / exit to reach the outward-facing side portion 13 of the horizontally positioned seatback 10 and raise it to its normal use position (hereinafter referred to as the "normal use position").

[0012] In this embodiment, the vehicle seat 100 has a maximum seating capacity of three people, but it may also have a capacity of two or one person. Furthermore, the vehicle seat 100 is installed in the vehicle body so that the occupants face the direction of travel, but it may also be installed so that the occupants face the opposite direction of travel, or it may be rotatable, allowing selection between a first position facing the direction of travel and a second position facing the opposite direction. In addition, the vehicle seat 100 is used in the rear seat of the vehicle, but it may also be used in the front seat of the vehicle.

[0013] When the seatbacks 10 and 102 are tilted forward, their front surfaces are pressed against the upper surface of the seat cushion 101, resulting in the aforementioned horizontal position and stability (see Figure 3). Furthermore, the seatback 10 of this embodiment is equipped with a special configuration to allow for easy raising of the horizontal seatback 10. The details of the structure of the seatback 10 will be described below.

[0014] The seat back 10 comprises a cushion member 11 and a surface material 30, such as a woven fabric, nonwoven fabric, or leather, that covers it. The cushion member 11 is, for example, a molded product of soft polyurethane foam. As shown in Figure 4, the cushion member 11 has a roughly rectangular shape when viewed from the front, and its front portion 12 is provided with a support portion 14 and a ridge portion 12A.

[0015] The support part 14 is arranged at the center in the vehicle width direction of the front part 12 and has a substantially flat surface against which the back of the occupant can abut. The side parts 12A are arranged at both ends in the vehicle width direction of the support part 14 and extend from the upper end to the vicinity of the lower end of the seat back 10. Further, the side parts 12A bulge forward to restrict the lateral movement of the occupant leaning on the support part 14. Furthermore, the tip part 15 of the cushion member 11 is provided with a through hole 15A for attaching the headrest 105 and a through hole 15B for attaching the seat belt.

[0016] Note that the foamed resin constituting the cushion member 11 is not limited to polyurethane-based resins, and any resin capable of foam molding may be used. Also, the foam structure may be an open-cell structure having air permeability or a closed-cell structure having no air permeability. Furthermore, the cushion member 11 of the seat back 10 may be equivalent to or softer than the cushion member 103 of the seat cushion 101, and the difference in hardness may be determined by any factors such as the foaming ratio, the type of raw material, the type and amount of the foaming agent, and the difference in molding conditions.

[0017] Inside the cushion member 11, a housing part 41 for housing the airbag module 40 is provided. The housing part 41 is arranged slightly above the center in the vertical direction of the seat back 10 and behind the side part 12A on the outer side part 13 side. Also, the airbag module 40 has an airbag bag body housed inside a substantially rectangular parallelepiped case and has an airbag bag body discharge port 40A on the front surface. Furthermore, a rupture part 42 for the inflated airbag bag body to pass through is provided at a position in front of the discharge port 40A of the side part 12A among the cushion member 11 and the skin material 30.

[0018] The seat back 10 in a horizontal posture is provided with a cover member 20 at a position above the breaking portion 42 on the side portion of the front surface portion 12 of the seat back 10 so that it can be easily returned to the normal use posture. The cover member 20 is a molded product formed by heat pressing a thermoplastic felt made of fibers such as polyethylene and polyester. Further, the basis weight of the thermoplastic felt is, for example, 700 g / cm2 to 1000 g / cm2 and is harder than the cushion member 11 and the seat cushion 101. Specifically, the cover member 20 has a hardness such that it does not deform even when pressed against the seat cushion 101 by the cushion member 11 when the seat back 10 is tilted to the horizontal posture.

[0019] As shown in FIG. 5, the cover member 20 has an L-shaped cross section where the first plate portion 21 and the second plate portion 22 intersect and extends in the vertical direction. And the cover member 20 is integrated with the cushion member 11 in a state where the first plate portion 21 is overlapped with the side portion of the front surface portion 12 (the embankment portion 12A) of the cushion member 11 and the second plate portion 22 is overlapped with the outer side portion 13 on the front surface portion 12 side, respectively.

[0020] Specifically, the first plate portion 21 is substantially rectangular in a front view, and the length in the width direction thereof is slightly narrower than the length in the width direction of the embankment portion 12A. Further, a plurality of through holes 23 penetrating in the front-rear direction are provided in the first plate portion 21, and the cushion member 11 is exposed therefrom (see FIG. 2). The outer edge portion of the exposed portion of the cushion member 11 from the through holes 23 is flush with the outer surface of the cover member 20, and the central portion is a recessed portion 24 and is recessed more than the outer surface of the cover member 20.

[0021] The multiple through holes 23 are circular in shape and are sized and positioned to accommodate, for example, the pads of fingertips. Specifically, the diameter of the through holes 23 is, for example, 1 cm to 3 cm. Of the multiple through holes 23, the first through hole 23A, which is located at the top, is positioned towards the inward side (support part 14 side) in the vehicle width direction of the first plate portion 21. The second and third through holes 23B and 23C, which are arranged vertically below the first through hole 23A, are positioned towards the outward side (outward facing side portion 13 side) in the vehicle width direction of the first plate portion 21. The first through hole 23A has a larger diameter than the two lower through holes 23B and 23C.

[0022] Furthermore, some of the through-holes 23 may be elliptical in shape with a minor axis of 1 cm to 3 cm. Also, all of the through-holes 23 may be circular, all may be elliptical, or there may be a mixture of circular and elliptical holes. Moreover, the through-holes 23 are not limited to circular shapes, but may also be square, other polygons, or other irregular shapes.

[0023] The second plate portion 22 has a roughly rectangular shape in plan view. The entire second plate portion 22, except for both ends in the vertical direction, has a wave-like shape, and the multiple recesses 25 and protrusions 26 that make up the wave shape extend along the entire front-to-back direction of the second plate portion 22. In other words, the recesses 25 of the second plate portion 22 open into the first plate portion 21. The width of the multiple recesses 25 is, for example, 1 cm to 3 cm. The connecting portion between the first plate portion 21 and the second plate portion 22 is a corner portion 22A with a rounded chamfer, and notches 27 are formed at the upper and lower ends of the corner portion 22A.

[0024] In this embodiment, three through holes 23 are formed in the first plate portion 21, but the number of through holes 23 may be less than three or more than three. The diameters of the multiple through holes 23 may all be the same or all be different. Also, the number of recesses 25 formed in the second plate portion 22 is not limited to three, but may be two or four or more. Furthermore, the number of through holes 23 formed in the first plate portion 21 and the number of recesses 25 formed in the second plate portion 22 may be the same or different. Moreover, the first plate portion 21 may be provided with multiple recesses 25 and the second plate portion 22 may be provided with multiple through holes 23. Also, only one of either multiple through holes 23 or multiple recesses 25 may be provided. Furthermore, the first and second plate portions 21 and 22 do not have to be flat, and may be curved in an arc shape as a whole.

[0025] This concludes the explanation of the structure of the seat back 10. Next, the manufacturing method of the seat back 10 will be described. First, thermoplastic felt is prepared and heated and pressed to form a cover member 20. Next, the cover member 20 is set in the lower mold 51 of the foam molding die 50. At this time, the cover member 20 is attached to an engagement part (not shown) provided on the cavity surface of the lower mold 51. Next, foaming material G is injected into the lower mold 51 and the upper mold 52 is closed (see Figure 6A).

[0026] As the mold remains closed, the foaming material G expands within the cavity, forming the cushion member 11. At this time, some of the foaming material G also penetrates between the fibers of the thermoplastic resin that make up the cover member 20. As a result, the cushion member 11 is formed to become one with the cover member 20 (Figure 6B). Next, the upper mold 52 is opened, and the cushion member 11 is removed from inside the cavity. Then, the surface material 30 is placed over the cushion member 11, completing the manufacturing of the seat back 10.

[0027] This concludes the explanation of the manufacturing method of the seat back 10. The following describes the function and effects of the seat back 10. In the vehicle seat 100 of this embodiment, when returning the seat back 10 from a horizontal position to a normal usage position, for example, one can insert a hand into the gap between the seat back 10 and the seat cushion 101 from the outward-facing side 13 to raise the seat back 10.

[0028] In this case, if the seat back 10 is not equipped with a cover member 20, as shown in Figure 8A, the difference in hardness between the two cushion members 11 and 103 of the seat back 10 and the seat cushion 101 causes one to bite into the other, resulting in a curved shape at the contact surface (boundary surface) between the seat back 10 and the seat cushion 101 when viewed from the front. Therefore, it becomes difficult to insert a finger from the side between the seat back 10 and the seat cushion 101 in order to raise the seat back 10.

[0029] In contrast, in this embodiment, as shown in Figure 8B, a portion of the front side of the cushion member 11 of the seat back 10 is covered with a cover member 20 that is harder than the seat cushion 101. As a result, even when the seat back 10 is tilted to a horizontal position, neither the seat cushion 101 nor the seat back 10 will dig into the other in the area where the cover member 20 is placed. Furthermore, it becomes easy to insert a finger between the seat back 10 and the seat cushion 101 along the front surface of the cover member 20, making it easier to raise the seat back 10.

[0030] Furthermore, since the first plate portion 21 that constitutes the front surface of the cover member 20 is provided with multiple through holes 23, the pads of the fingertips can be placed in these through holes 23 via the surface material 30 of the seat back 10, preventing the fingertips from slipping. In addition, since the cover member 20 is positioned above the rupture portion 42, it does not obstruct the ejection of the airbag bag.

[0031] Furthermore, the foaming material G penetrates between the fibers that make up the thermoplastic felt, causing the cover member 20 and the cushion member 11 to become firmly integrated. In addition, the integral molding of the cover member 20 with the cushion member 11 ensures stable fixation between the two, and allows the outer surfaces of the cover member 20 and the cushion member 11 to be flush and continuous, resulting in a pleasing appearance.

[0032] Furthermore, the cover member 20 is provided with a first plate portion 21 that covers the side portion of the front portion 12 (embankment portion 12A) of the cushion member 11, and a second plate portion 22 that covers the outward-facing side portion 13 on the front portion 12 side, thereby suppressing the separation between the cover member 20 and the cushion member 11. In addition, the formation of a notch 27 in the corner portion 22A of the cover member 20 further suppresses the separation between the cover member 20 and the cushion member 11.

[0033] [Other embodiments] (1) In the above embodiment, the cover member 20 spanned the front portion 12 and the outward-facing side portion 13 of the cushion member, but it may consist of only the first plate portion 21 or the second plate portion 22. Even if only the first plate portion 21 is provided, the cover member 20 can prevent the seat back 10 from digging in, making it easier to insert a hand. Alternatively, only the second plate portion 22 may be provided.

[0034] (2) The recess 25 formed in the second plate portion 22 of the cover member 20 does not have to be a groove extending in the front-rear direction, and may be provided only at the corner portion 22A between the first plate portion 21 and the second plate portion 22, as shown in Figure 7A.

[0035] (3) In the above embodiment, the recess 25 of the second plate portion 22 was a bottomed groove, but as shown in Figure 7B, it may be an open recess 25A that exposes a part of the cushion member 11. Furthermore, as shown in Figure 7C, a part of the open recess 25A may communicate with the through hole 23 of the first plate portion 21.

[0036] (4) In the above embodiment, the convex portion 26 and the concave portion 25 are formed on the second plate portion 22, but they may also be formed on the first plate portion 21. As shown in Figure 9, the entire first plate portion 21, except for both ends in the vertical direction, has a wave shape, and the plurality of concave portions 28 and convex portions 29 that constitute the wave shape may extend in the width direction (vehicle width direction) of the first plate portion 21 from the through hole 23 to the corner portion 22A. In other words, the first plate portion 21 may be provided with a concave portion 28 that opens into the second plate portion 22. By providing a concave portion 28 on the first plate portion 21, it becomes even easier to insert a finger between the seat back 10 and the seat cushion 101 along the front surface of the cover member 20. Also, since the concave portion 28 is in communication with the through hole 23, it is possible to extend a fingertip into the through hole 23 through the concave portion 28. Furthermore, the recess 28 of the first plate portion 21 may be continuous with the recess 25 of the second plate portion 22, and the protrusion 29 of the first plate portion 21 may be continuous with the protrusion 26 of the second plate portion 22.

[0037] (5) The cushion member 11 of the seat back 10 may be harder than, the same hardness as, or softer than the cushion member 103 of the seat cushion 101. If the cushion member 11 of the seat back 10 is harder than the cushion member 103 of the seat cushion 101, as in the first embodiment described above, when the seat back 10 is placed in a horizontal position, the seat cushion 101 will be compressed and deformed and sink in, so the effect of providing the cover member 20 can be enjoyed to a greater extent.

[0038] (6) The cover member 20 may also be an injection-molded resin product or a press-molded sheet metal product, but if it is a heat-press-molded thermoplastic felt product as in the present invention, the cover member 20 can be manufactured using inexpensive equipment.

[0039] <Note> The following describes the features extracted from the above embodiment, explaining their effects and other aspects as needed. For ease of understanding, corresponding configurations in the above embodiment will be indicated in parentheses as appropriate, but these features are not limited to the specific configurations indicated in parentheses.

[0040] [Feature 1] A foldable seat back (10) that folds toward a seat cushion (101), comprising a cushion member (11) and a cover member (20) that covers a part of the front side portion (13) of the cushion member (11) and is harder than the seat cushion (101), wherein the cover member (20) is integrally molded with the cushion member (11).

[0041] According to Feature 1, a portion of the front side of the seatback cushion is covered with a cover member that is harder than the seat cushion. As a result, even when the seatback is tilted to a horizontal position, neither the seat cushion nor the seatback will dig into the other in the area where the cover member is positioned. Furthermore, it becomes easy to insert a finger between the seatback and the seat cushion along the front of the cover member, making it easier to raise the seatback.

[0042] [Feature 2] The seat back (10) according to feature 1, wherein the cover member (20) is provided with a through hole (23) on its front surface.

[0043] According to Feature 2, since a finger can be placed in the through-hole, the benefits of having a cover member can be more fully realized.

[0044] [Feature 3] The seat back (10) according to feature 1, wherein the cover member (20) has a first plate portion (21) that covers the front side portion (13) of the cushion member (11), and a second plate portion (22) that bends from the first plate portion (21) and covers the side of the cushion member (11) on the front side portion (13) side.

[0045] According to Feature 3, even if the seat back, which is positioned horizontally, sinks into the seat cushion, it is possible to place fingers on the corner between the first and second plates, making it easier to insert a hand into the gap between the first plate of the cover member and the seat cushion. In addition, by integrally molding the L-shaped cover member to the corner between the front and outward-facing sides of the seat back, the cover member is less likely to fall off.

[0046] [Feature 4] The seat back (10) according to feature 3, wherein the first plate portion (21) is provided with a recess (25) that opens into the second plate portion (22).

[0047] According to Feature 4, since a finger can be placed on the first plate through the recess opening in the second plate, the benefits of the cover member being composed of a first plate and a second plate can be more fully enjoyed.

[0048] [Feature 5] A seat back (10) of the rear seat of a vehicle, as described in any one of the features 1 to 4.

[0049] The seatback may be used in the rear seats of a car, or it may be applied to the driver's seat or passenger seat. Furthermore, it may be used not only in automobiles, but also as seats in trains, ships, and other vessels.

[0050] [Feature 6] A vehicle seat (100) comprising a seat back (10) described in any one of the features 1 to 4, and the seat cushion (101).

[0051] While this specification and drawings disclose specific examples of the technology included in the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and changes to these examples, as well as parts of the examples taken individually. [Explanation of Symbols]

[0052] 10 Seatback 11 Cushioning material 12 Front part 12A Embankment 13 Outward-facing side 20 Cover component 21 1st plate part 22 2nd plate part 23 Through hole 25 recesses 100 Vehicle Seats 101 Seat Cushion

Claims

1. It is a foldable seatback that tilts towards the seat cushion, Cushioning material and The cushion member comprises a cover member that covers a portion of the front side of the cushion member and is harder than the seat cushion, The cover member is a seat back that is integrally molded with the cushion member.

2. The seat back according to claim 1, wherein the cover member is provided with a through hole on its front surface.

3. The seat back according to claim 1, wherein the cover member comprises a first plate portion that covers the front side portion of the cushion member, and a second plate portion that bends from the first plate portion and covers the side portion of the cushion member on the front side portion side.

4. The seat back according to claim 3, wherein the first plate portion is provided with a recess that opens to the second plate portion.

5. A seat back for the rear seat of a vehicle, according to any one of claims 1 to 4.

6. A vehicle seat comprising a seat back according to any one of claims 1 to 4 and the seat cushion.

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