Vehicle seat and method for manufacturing a vehicle seat

Abstract

The present invention relates to a vehicle seat that can maintain the occupant's head in a desirable position even when subjected to large acceleration, and to a method for manufacturing a vehicle seat. [Solution] The vehicle seat 10 comprises a seat back frame 22 and a headrest 40 attached to the upper part of the seat back frame 22. The headrest 40 comprises a frame member 41 supported by the seat back frame 22 and a cover member 44 that covers the frame member 41 and has a front wall portion 441a facing forward in the front-rear direction of the seat. The cover member 44 has a through hole 443 in the front wall portion 441a, and when viewed from the front-rear direction of the seat, the frame member 41 is positioned to overlap with the through hole 443.

Description

Technical Field

[0001] The present disclosure relates to a vehicle seat on which an occupant sits and a method for manufacturing the vehicle seat.

Background Art

[0002] A vehicle seat includes a seat back and a seat cushion. A headrest for supporting the head of an occupant is attached to the upper part of the seat back. The headrest has a frame member that constitutes the skeleton of the headrest, a cover member that covers the frame member, and a cushion and a skin material that cover the surface of the cover member. The frame member is made of a high-strength member such as metal and is connected to the seat back frame. Further, the cover member is formed of a resin material that is more flexible than the frame member. The cover member covers the edge of the frame member and protects the occupant from the frame member and its edge. For example, Japanese Patent Application Laid-Open No. 2016-078625 (Patent Document 1) describes an example of a headrest.

Prior Art Documents

Patent Documents

[0003]

Patent Document l

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a conventional headrest, in the front-rear direction of the seat, the front of the frame member is covered with a cover member, and there is a gap in the front-rear direction of the seat between the frame member and the cover member. Therefore, for example, when a large acceleration is applied to the vehicle, the cover member receives the load of the occupant's head and greatly deform. In this case, there is a problem that the position supporting the occupant's head shifts backward from the assumed support position.

[0005] An object of the present disclosure is to solve the above-described problems. [Means for solving the problem]

[0006] A first aspect of the present disclosure is a vehicle seat comprising a seat back frame and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises a frame member supported by the seat back frame and a cover member covering the frame member and having a front wall portion facing forward in the seat front-rear direction, the cover member having a through hole in the front wall portion, and the frame member being positioned to overlap the through hole when viewed from the seat front-rear direction.

[0007] A second aspect of the present disclosure is a method for manufacturing a vehicle seat, comprising: a seat back frame; and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises: a frame member supported by the seat back frame; and a cover member covering the frame member and having a front wall portion facing forward in the seat front-rear direction, wherein the cover member has a through hole in the front wall portion, and the frame member is positioned to overlap the through hole when viewed from the seat front-rear direction, the method for manufacturing a vehicle seat comprising: a first step of attaching the cover member to the frame member; and a second step of attaching the headrest to the seat back frame after the first step. [Effects of the Invention]

[0008] According to this disclosure, the frame member can support the occupant's head through the through-hole in the cover member, so that the occupant's head can be held in a favorable position even when a large acceleration is applied. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a schematic perspective view of a vehicle seat according to an embodiment. [Figure 2] Figure 2 is a perspective view of the frame structure of a vehicle seat. [Figure 3]Figure 3 is a partially abbreviated cross-sectional view showing the positional relationship between the protruding surface of the frame member and the blower and duct, as viewed from the sheet width direction. [Figure 4] Figure 4A is a perspective view of the connection structure that connects the headrest pillar and the frame assembly, and Figure 4B is an exploded perspective view showing the connection structure of Figure 4A in a disconnected state. [Figure 5] Figure 5 is an exploded perspective view of the headrest shown in Figure 1. [Figure 6] Figure 6 is an exploded perspective view of the frame assembly from Figure 4A, taken from a diagonal rearward angle. [Figure 7] Figure 7 is a cross-sectional view of the lower end of the frame assembly. [Figure 8] Figure 8 is a front view of the cover member, frame member, and headrest pillar shown in Figure 2. [Figure 9] Figure 9 is a partially abbreviated perspective view of the first surface of the rear wall. [Figure 10] Figure 10 is a cross-sectional view from above of the engagement portion between the frame member and the second cover member. [Figure 11] Figure 11 is a perspective view of the headrest frame assembly shown in Figure 1. [Figure 12] Figure 12 is a partially abbreviated cross-sectional view showing the connection point between the headrest and the headrest pillar and its surrounding area. [Figure 13] Figure 13 is a partially abbreviated front view showing the arrangement of the frame assembly and connecting structure in Figure 4A, viewed from the front. [Figure 14] Figure 14 is a partially abbreviated side view showing the positional relationship between the airbag and the protruding surface of the headrest in Figure 1, as viewed from the seat width direction. [Figure 15] Figure 15 is a flowchart showing a method for manufacturing a vehicle seat according to an embodiment. [Modes for carrying out the invention]

[0010] In the following description, the terms front, rear, right, left, top, and bottom are used. Front and rear represent the relative positional relationship in the front-rear direction of the seat shown in FIG. 1. Note that the front-rear direction of the seat may be the same as the front-rear direction of a vehicle (e.g., an automobile). Right and left indicate the relative positional relationship in the width direction of the seat shown in FIG. 1. The width direction of the seat is a direction orthogonal to the front-rear direction of the seat and may be the same as the width direction of the vehicle. Top and bottom indicate the relative positional relationship in the up-down direction orthogonal to the front-rear direction and the width direction of the seat as shown in FIG. 1. Note that in this specification, the term up-down direction of the seat is also used. The up-down direction of the seat is a direction along the longitudinal direction of the seat back 20.

[0011] The vehicle seat 10 shown in FIG. 1 is, for example, a passenger seat of a right-hand drive four-wheel automobile not shown. However, the vehicle seat 10 may be a seat for other seats than the passenger seat. Also, the vehicle seat 10 is not limited to an automobile seat mounted on a right-hand drive four-wheel automobile. The vehicle seat 10 may be an aircraft seat or a railway vehicle seat.

[0012] As shown in FIG. 1, the vehicle seat 10 includes a seat back 20, a seat cushion 30, a headrest 40, and an airbag 50.

[0013] The seat cushion 30 has a cushion frame 32 and a seat surface cushion 34. The cushion frame 32 is supported by seat rails S1 and S2 so as to be movable in the front-rear direction of the seat. The vehicle seat 10 moves in the front-rear direction of the seat along the two seat rails S1 and S2 by the operation of the occupant. The seat surface cushion 34 is formed of, for example, a urethane cushion material and a skin sheet covering the cushion material, and is supported by the cushion frame 32.

[0014] As shown in FIGS. 1 and 2, the seat back 20 has a seat back frame 22, a seat back cushion 24, a blower unit 26, and a headrest pillar 28. The seat back frame 22 is formed in a substantially rectangular shape with the length in the seat vertical direction being greater than the length in the seat width direction. The seat back frame 22 has a pair of left and right frame bodies 221 and a connecting frame 222 that connects the upper portions of the pair of frame bodies 221. The seat back frame 22 is connected to a cushion frame 32 via a reclining mechanism 29. The reclining mechanism 29 rotatably connects the seat back 20 to the seat cushion 30.

[0015] Hereinafter, the vertical positional relationship among the seat back 20, the headrest 40, the headrest pillar 28, and their components will be described based on the state where the seat back 20 is not inclined in the front-rear direction with respect to the seat cushion 30 (the reclining angle is 0°) as shown in FIG. 1. The state where the seat back 20 is not inclined in the front-rear direction means the state where the headrest 40 is arranged above the seat back 20 in the vertical direction.

[0016] The seat back cushion 24 is supported by the seat back frame 22. The seat back cushion 24 has, for example, a cushion material such as urethane foam and a skin material that covers the surface of the cushion material. The seat back cushion 24 covers the front of the blower unit 26.

[0017] As shown in FIG. 2, the blower unit 26 is attached to the seat back frame 22. The blower unit 26 is located at the center in the seat width direction of the seat back 20 and is attached to the connecting frame 222 of the seat back frame 22. The blower unit 26 includes a blower 261 having a built-in blower fan and a duct 262 connected to the blower 261. The blower 261 sends air into the seat back cushion 24 through the duct 262. Note that the blower 261 may be configured to suck air from the seat back cushion 24 through the duct 262.

[0018] The blower 261 protrudes downward from the connecting frame 222. The duct 262 is attached to the bottom of the blower 261. The duct 262 bends forward and opens forward. A bracket 263 is provided on the side of the blower unit 26. The bracket 263 is a plate-shaped member that extends vertically and is attached so as to protrude downward from the connecting frame 222. The bracket 263 is equipped with a clip 265 to hold the harness 264 that supplies power to the blower 261. The clip 265 is a member fitted into the bracket 263 and has a holding part (not shown) on the rear side of Figure 2 that holds the harness 264.

[0019] As shown in Figure 3, the blower 261 and duct 262 are positioned behind the protruding surface 415 of the protruding portion 413 of the headrest 40, which will be described later, in the seat-forward direction. With the blower unit 26 positioned in this way, protrusion onto the seat back cushion 24 is suppressed, thus preventing excessive seating load from being applied to the blower unit 26 when an occupant is seated.

[0020] As shown in Figures 1 and 2, the headrest pillar 28 is joined to the connecting frame 222 of the seat back frame 22 by welding or the like. The headrest pillar 28 is formed from a metal pipe, such as iron. The headrest pillar 28 has an inverted U shape when viewed from the front-rear direction of the seat. The headrest pillar 28 has two legs 281 spaced apart in the seat width direction and a pillar upper part 282 that connects the upper parts of the legs 281. The legs 281 extend in the vertical direction. The lower ends of the legs 281 are joined to the seat back frame 22. The headrest 40 is connected to the pillar upper part 282 via a connecting structure 280 shown in Figure 4A.

[0021] As shown in Figures 4A and 4B, the upper part of the pillar 282 extends in the seat width direction and is integrally connected to the two leg portions 281. A connecting structure 280 is attached to the upper part of the pillar 282. The connecting structure 280 has a mounting stay 283. The mounting stay 283 is joined to the upper part of the pillar 282 by welding or the like. The mounting stay 283 has a front wall 284 facing forward. A pair of connecting holes 285 for fixing the headrest 40 are formed in the front wall 284. Bolts 432 extending from the headrest 40 pass through the connecting holes 285. The headrest pillar 28 configured as described above is covered by a pillar cover 286 made of, for example, resin, as shown in Figure 1.

[0022] As shown in Figure 1, the headrest 40 is attached to the top of the seat back 20. The headrest 40 is connected to the seat back frame 22 via the headrest pillar 28.

[0023] As shown in Figure 5, the headrest 40 comprises a frame member 41, a connecting part 43, a cover member 44, a headrest pad 45, a slab 46, a headrest surface 47, a back panel 48, and a support pipe 49.

[0024] The cover member 44 is made of a material that is less rigid than the frame member 41, such as resin. The cover member 44 protects the occupants from the edges of the frame member 41 by covering the perimeter of the frame member 41.

[0025] As shown in Figures 5 and 6, the cover member 44 has a first cover member 441 that covers the front of the frame member 41 and a second cover member 442 that covers the rear of the frame member 41. The first cover member 441 has a front wall portion 441a that faces forward in the front-rear direction of the seat. The second cover member 442 has a rear wall portion 442a that faces rearward in the front-rear direction of the seat. A through hole 443 is formed in the front wall portion 441a. The through hole 443 is formed in a substantially rectangular shape when viewed from the front-rear direction of the seat and penetrates the first cover member 441 in the front-rear direction of the seat. When viewed from the front-rear direction of the seat, the frame member 41 is positioned to overlap with the through hole 443. Three mounting holes 411 for attaching screws 440 are formed at predetermined locations in the first cover member 441.

[0026] As shown in Figure 7, a short, forward-projecting front projection 444 is formed at the lower part of the first cover member 441. The front projection 444 protrudes further forward than the protruding surface 415 of the frame member 41, which will be described later. This front projection 444 improves the support force for the occupant's head at the lower part of the headrest 40 when a large forward acceleration occurs. The portion of the first cover member 441 from below the lower end of the through hole 443 to the front projection 444 forms a first lower edge 455 that slopes to gradually protrude forward as it goes downward. The first lower edge 455 has a curved portion, but as a whole it slopes along the support pipe 49, as shown in Figure 12. The first lower edge 455 is formed to be parallel to the second lower edge 456, which will be described later.

[0027] As shown in Figures 5 and 6, the second cover member 442 has the same external shape as the first cover member 441 when viewed from the front-rear direction of the seat. The second cover member 442 is positioned at the rear of the frame member 41 and accommodates the peripheral wall portion 42 of the periphery of the frame member 41. The second cover member 442 (rear wall portion 442a) has a first surface 446 facing forward and a second surface 447 formed on the opposite side of the first surface 446 and facing rear.

[0028] As shown in Figure 9, a receiving portion 448 and an insert bush 449 are formed on the first surface 446 of the second cover member 442. The receiving portion 448 is located near the lower end of the second cover member 442 and protrudes forward from the first surface 446. The receiving portion 448 extends in the sheet width direction. As shown in Figure 7, the receiving portion 448 engages with the protrusion 421 of the frame member 41 to prevent misalignment between the frame member 41 and the second cover member 442. As shown in Figure 5, the insert bush 449 protrudes forward from the first surface 446. The insert bush 449 is provided in the portion corresponding to the mounting hole 411 of the first cover member 441. A screw 440 is tightened into the insert bush 449.

[0029] As shown in Figure 6, a protrusion 450 is formed on the second surface 447 of the second cover member 442. The protrusion 450 extends in the sheet width direction. As shown in Figure 7, the protrusion 450 protrudes rearward, in the opposite direction to the protrusion direction of the receiving portion 448. The protrusion 450 is located behind the receiving portion 448. The protrusion 450 is positioned so as to overlap with the receiving portion 448 when viewed from the front-rear direction of the sheet. The protrusion 450 prevents misalignment between the frame member 41 and the second cover member 442 by increasing the rigidity of the receiving portion 448.

[0030] As shown in Figure 6, an insertion hole 451 is formed in the center of the second cover member 442 in the width direction and vertical direction of the seat. The insertion hole 451 is a rectangular hole that penetrates the second cover member 442 in the front-rear direction of the seat and has dimensions that allow the connecting portion 43 to pass through. As shown in Figure 6, the vertical length L2 of the insertion hole 451 of the second cover member 442 is smaller than the vertical length L1 of the through hole 443 of the first cover member 441. By making the vertical length L2 of the insertion hole 451 smaller than the vertical length L1 of the through hole 443 in this way, a decrease in the rigidity of the second cover member 442 can be prevented, and the decrease in the overall rigidity of the headrest 40 is suppressed.

[0031] The insertion hole 451 is positioned so as to overlap with the through hole 443 when viewed from the front-to-rear direction of the seat. This arrangement increases the rigidity of the headrest 40 compared to the case where the through hole 443 and the insertion hole 451 do not overlap, allowing for more reliable support of the occupant's head load.

[0032] As shown in Figure 6, the second cover member 442 has a plurality of hooks 452 and two engaging portions 453 on the second surface 447. The hooks 452 are arranged in a plurality along the outer circumference of the second cover member 442. The hooks 452 hold the trim cords 471 of the headrest surface 47, which will be described later (see Figure 12). The engaging portions 453 are groove-shaped portions that extend downward from the lower edge of the insertion hole 451, and two are provided spaced apart in the seat width direction. The engaging portions 453 are formed to protrude rearward from the second surface 447. The hook portions 472 provided on the edge of the headrest surface 47 are hooked onto the engaging portions 453 (see Figure 12).

[0033] As shown in Figures 3, 4, 7, and 12, a second lower edge 456 is formed on the lower end of the second cover member 442 in the vertical direction. The second lower edge 456 slopes forward as it goes downward. The second lower edge 456 is parallel to the first lower edge 455 and is formed parallel to the upper inclined portion 200a of the outer shape 200 of the seat back 20. When the load of the seated person's head is applied and the lower part of the headrest 40 flexes, the first lower edge 455 and the second lower edge 456 of the first cover member 441 and the second cover member 442 come into contact with the upper part of the seat back 20. As a result, the first cover member 441 and the second cover member 442 can properly transmit the load to the upper inclined portion 200a of the seat back 20.

[0034] As shown in Figure 5, the frame member 41 is formed in the shape of a thin plate that is thin and spread out in the width direction and vertical direction of the sheet. The frame member 41 is made of a material with excellent strength, such as steel plate. When viewed from the front, the frame member 41 is formed in the shape of a trapezoid where the top side is narrower than the bottom side.

[0035] As shown in Figure 8, in a front view, the right edge 41r and left edge 41l of the frame member 41 are positioned inward in the width direction relative to the right edge 441r and left edge 441l of the first cover member 441. This configuration allows for a wider surface area on which the first cover member 441 can support the head of a seated person, while suppressing an increase in the width of the frame member 41.

[0036] The frame member 41 has a projection 413 in the center in the width direction of the sheet. The projection 413 is a portion that protrudes forward from the peripheral edge 414 of the frame member 41 and is integrally connected to the peripheral edge 414 via a step. When viewed from the front-rear direction of the sheet, the projection 413 is formed in a rectangular shape with rounded corners. The projection 413 has a forward-facing projection surface 415. Although not particularly limited, the projection 413 may have a plurality of punching holes 413a formed therein.

[0037] As shown in Figure 11, the protrusion 413 of the frame member 41 has dimensions slightly smaller than the through hole 443 formed in the first cover member 441. The protrusion 413 passes through the through hole 443 and protrudes forward of the first cover member 441. As shown in Figure 12, the protrusion 413 is not covered by the cover member 44 and is in direct contact with the headrest pad 45. Such a protrusion 413 can support the load of the occupant's head with high rigidity by receiving the load of the occupant's head without going through the first cover member 441. As shown in Figures 5 and 6, the protrusion 413 occupies more than half of the dimensions of the headrest 40 in the seat width direction and vertical direction. As shown in Figure 10, the dimension W1 of the protrusion 413 in the seat width direction is larger than the dimension W2 of the receiving portion 448 of the second cover member 442 in the seat width direction. Such a protrusion 413 has excellent load-bearing capacity for the occupant's head.

[0038] As shown in Figure 5, the peripheral portion 414 is positioned to surround both sides and the top of the protruding portion 413 in the sheet width direction. The front and outer sides of the peripheral portion 414 are covered by the first cover member 441 of the cover member 44. Three mounting holes 416 are formed in the peripheral portion 414 through which three screws 440 are inserted. The three mounting holes 416 are positioned to overlap with the mounting holes 411 of the first cover member 441.

[0039] As shown in Figure 6, a peripheral wall portion 42 is formed at the outer peripheral end of the frame member 41, including the protruding portion 413 and the peripheral edge portion 414, and extends in a curve toward the rear. The peripheral wall portion 42 is formed to surround the outer circumference of the frame member 41.

[0040] As shown in Figures 7 and 10, a projection 421 is formed on the peripheral wall portion 42 at the lower end of the frame member 41, projecting backward. The projection 421 has two convex portions 422 and a concave portion 423. The convex portions 422 are portions that project further backward than the rest of the peripheral wall portion 42. The two convex portions 422 are spaced apart in the sheet width direction. The concave portion 423 is formed between the two convex portions 422. The concave portion 423 has a shorter rearward projection length than the convex portions 422 and is concave when viewed from above. The projection 421 engages with the receiving portion 448 of the second cover member 442 at the concave portion 423. By engaging with the second cover member 442, the concave portion 423 prevents the cover member 44 from shifting relative to the frame member 41 in the sheet front-rear direction and the sheet width direction.

[0041] As shown in Figures 5 and 6, the frame member 41 is joined to the connecting portion 43 and the support pipe 49. The connecting portion 43 is joined to the rear surface of the protruding portion 413 of the frame member 41 by welding or the like. The connecting portion 43 is formed in a U-shape when viewed from above. As shown in Figure 6, the connecting portion 43 has a rearward-facing connecting wall 431 at its rear end. Two bolts 432 are joined to the connecting wall 431 by welding. The bolts 432 pass through the bolt holes 433 of the connecting wall 431 and protrude to the rear of the connecting wall 431. As shown in Figure 4B, the connecting portion 43 protrudes rearward through the insertion hole 451 of the second cover member 442. The connecting portion 43 is attached to the headrest pillar 28 via the connecting wall 431 and the bolts 432.

[0042] As shown in Figure 6, the support pipe 49 is joined to the lower end of the frame member 41. The support pipe 49 extends long in the width direction of the seat and is formed in a U shape when viewed from the front-rear direction of the seat. The upper end of the support pipe 49 is welded to the frame member 41. As shown in Figure 7, the support pipe 49 extends shortly diagonally downward towards the front. The support pipe 49 is positioned inside the front projection 444 of the first cover member 441 and supports the front projection 444 and the first lower edge 455.

[0043] As shown in Figure 11, the frame member 41, the connecting part 43, the cover member 44, and the support pipe 49 are assembled together to form a frame assembly 410. As shown in Figure 6, the frame member 41 is positioned inside the cover member 44, sandwiched between the first cover member 441 and the second cover member 442 of the cover member 44 from the front-rear direction of the seat. As shown in Figure 11, the frame member 41, the first cover member 441, and the second cover member 442 are connected by fastening together with three screws 440.

[0044] As shown in Figure 12, the headrest pad 45 is made of, for example, urethane sponge and is attached to cover the front of the frame assembly 410. A recess 454 is formed on the front surface of the headrest pad 45. A slab 46 is fitted into the recess 454 and joined with adhesive or the like. The slab 46 is a flexible plate-like member made of, for example, foamed resin material, and improves the head's hold by giving the headrest 40 an appropriate firmness. The vertical length L3 of the slab 46 is greater than the vertical length L4 of the protrusion 413. In this way, increasing the vertical length L3 of the slab 46 increases the support force for the occupant's head.

[0045] The headrest cover 47 is attached so as to cover the outside of the headrest pad 45 and the slab 46. The edge of the headrest cover 47 is positioned to wrap around the rear of the frame assembly 410 and is attached to the rear of the second cover member 442.

[0046] A trim cord 471 is provided on the edge of the headrest upholstery 47. The trim cord 471 is hooked onto and held by a hook 452 on the second cover member 442. In addition, a pair of hook portions 472 are attached to other parts of the edge of the headrest upholstery 47. The hook portions 472 have a J-shaped cross-section. The hook portions 472 are hooked onto and held by an engaging portion 453 on the second cover member 442. In this way, the headrest upholstery 47 is fixed to the second cover member 442.

[0047] The back panel 48 is attached to the rear of the second cover member 442 of the cover member 44. The back panel 48 covers the connection between the second cover member 442 and the headrest upholstery 47. The back panel 48 has an opening 481 that exposes the connecting portion 43 to the rear. The opening 481 allows the mounting stay 283 to pass through. The headrest 40 is fixed to the mounting stay 283 of the headrest pillar 28 through the connecting portion 43 exposed in the opening 481. The bolt 432 passes through the connecting hole 285 of the mounting stay 283. The nut 287 is tightened onto the bolt 432 from the rear of the mounting stay 283, thereby fixing the headrest 40 to the headrest pillar 28.

[0048] As shown in Figure 13, when viewed from the front-to-rear direction of the seat, the bolts 432 that secure the headrest 40 to the headrest pillar 28 are positioned inside a virtual triangular region T formed by the three screws 440 that connect the frame assembly 410. By positioning the bolts 432 in this way, the load in the front-to-rear direction of the seat can be effectively transmitted to the headrest pillar 28, and the headrest 40 is more firmly fixed to the headrest pillar 28.

[0049] As shown in Figure 1, in the vehicle seat 10, the airbag 50 is located on the left side of the seat back 20. The airbag 50 is housed in an airbag storage compartment 52 located on the seat back 20. The airbag 50 deploys in the event of an unforeseen incident to protect the occupant from side impacts. If the vehicle seat 10 is for the right seat, the airbag 50 is located on the right side of the seat back 20.

[0050] As shown in Figure 14, a portion (the rear end) of the airbag 50 is located behind the protruding surface 415. With this configuration, the airbag 50 deploys when the vehicle detects a significant impact. At that time, the headrest 40 can support the occupant's head near the deployment area of ​​the airbag 50. This allows the vehicle seat 10 to protect the occupant's head more effectively.

[0051] The vehicle seat 10, configured as described above, is manufactured by the following process.

[0052] As shown in Figure 15, the seat back 20 and the seat cushion 30 are assembled (S10).

[0053] Next, the cover member 44 is attached to the frame member 41 to assemble the frame assembly 410 (S20, first step). Specifically, the joint 43 and support pipe 49 are joined to the frame member 41 by welding. Then, the first cover member 441 is attached to the frame member 41 from the front, and the second cover member 442 is attached from the rear. After that, the first cover member 441, the frame member 41, and the second cover member 442 are fixed together with screws 440 to complete the frame assembly 410.

[0054] Next, the headrest pad 45, slab 46, and headrest upholstery 47 are attached to the frame assembly 410 (S30). The headrest 40 is completed through these steps.

[0055] Next, the headrest 40 is attached to the headrest pillar 28 (seat back frame 22) (S40, second step). Through these steps, the vehicle seat 10 is completed. A vehicle seat 10 manufactured by this method can directly support the occupant's head with the frame member 41 when the occupant is seated, and has excellent support for the occupant's head.

[0056] This embodiment provides the following effects.

[0057] As shown in Figure 2, the headrest 40 of the vehicle seat 10 has a frame member 41 supported by the seat back frame 22 and a cover member 44 that covers the frame member 41. The cover member 44 has a through hole 443 in its front wall portion 441a. When viewed from the front-rear direction of the seat, the frame member 41 is positioned to overlap with the through hole 443.

[0058] With this configuration, the frame member 41 directly supports the headrest pad 45 without being covered by the cover member 44, thus suppressing the rearward movement of the occupant's head even when a large acceleration is applied.

[0059] As shown in Figure 3, the frame member 41 has a projection 413 that passes through the through hole 443 and protrudes forward from the front wall portion 441a of the cover member 44.

[0060] With this configuration, the frame member 41 can receive the load of the occupant's head at a position that protrudes forward from the front wall portion 441a of the cover member 44, thereby further improving the occupant's head support performance.

[0061] As shown in Figure 3, the headrest 40 further has a connecting portion 43 for supporting the frame member 41 to the seat back frame 22. The cover member 44 also has a rear wall portion 442a facing rearward in the seat front-rear direction. The frame member 41 is positioned between the front wall portion 441a and the rear wall portion 442a. An insertion hole 451 for the connecting portion 43 is formed in the rear wall portion 442a, and when viewed from the seat front-rear direction, the insertion hole 451 is positioned to overlap with the through hole 443.

[0062] With this configuration, the load from the occupant's head, received by the protruding portion 413, is efficiently transmitted to the seat back frame 22 via the connecting portion 43, thereby ensuring reliable support for the head.

[0063] As shown in Figure 6, the vertical length L2 of the insertion hole 451 is smaller than the vertical length L1 of the through hole 443.

[0064] This configuration suppresses the overall reduction in rigidity of the cover member 44, thereby improving the strength of the headrest 40.

[0065] As shown in Figure 10, the frame member 41 has a projection 421 that protrudes toward the rear wall portion 442a. The rear wall portion 442a is provided with a receiving portion 448 that engages with the projection 421.

[0066] With this configuration, the frame member 41 and the cover member 44 are securely fixed together, and misalignment between the frame member 41 and the cover member 44 can be prevented.

[0067] The protrusion 421 has a plurality of convex portions 422 and concave portions 423 formed between the convex portions 422. The protrusion 421 engages with the receiving portion 448 at the concave portions 423.

[0068] This configuration makes it possible to more effectively prevent misalignment of the frame member 41 and the cover member 44 in the sheet width direction.

[0069] The dimension W1 of the protruding portion 413 in the sheet width direction is greater than the dimension W2 of the receiving portion 448 in the sheet width direction.

[0070] With this configuration, the larger dimensions of the protrusion 413 in the seat width direction improve the support performance for the occupant's head.

[0071] As shown in Figure 7, the second cover member 442 has a first surface 446 on which a receiving portion 448 is provided, and a second surface 447 opposite to the first surface 446. The receiving portion 448 protrudes from the first surface 446. The second surface 447 has a convex portion 450 that protrudes in the direction opposite to the protrusion direction of the receiving portion 448.

[0072] With this configuration, the receiving portion 448 and the protruding portion 450 are formed to overlap, thereby improving the rigidity of the receiving portion 448 of the second cover member 442.

[0073] As shown in Figure 14, the protruding portion 413 of the frame member 41 has a protruding surface 415 that supports the occupant's head. The rear end of the airbag 50 is located behind the protruding surface 415 in the seat-forward direction.

[0074] With this configuration, the headrest 40 can support the occupant's head near the deployment area of ​​the airbag 50. This allows the vehicle seat 10 to protect the occupant's head more effectively.

[0075] As shown in Figure 15, the manufacturing method of the vehicle seat 10 includes a first step (S20) of attaching a cover member 44 to a frame member 41, and a second step (S40) of attaching a headrest 40 to a seat back frame 22 after the first step.

[0076] This method makes it possible to manufacture a vehicle seat 10 that offers superior protection for the occupant's head.

[0077] With regard to the embodiments described above, the following additional information is disclosed.

[0078] (Note 1) The vehicle seat (10) of the present disclosure is a vehicle seat comprising a seat back frame (22) and a headrest (40) attached to the upper part of the seat back frame, wherein the headrest comprises a frame member (41) supported by the seat back frame and a cover member (44) that covers the frame member and has a front wall portion (441a) facing forward in the front-rear direction of the seat, the cover member having a through hole (443) in the front wall portion, and the frame member is positioned to overlap the through hole when viewed from the front-rear direction of the seat.

[0079] (Note 2) The vehicle seat described in Appendix 1, wherein the frame member may have a protruding portion (413) that passes through the through hole and protrudes forward from the front wall portion of the cover member.

[0080] (Note 3) A vehicle seat as described in Appendix 2, further comprising a connecting portion (43) joined to the rear surface of the protruding portion and for supporting the frame member on the seat back frame, wherein the cover member has a rear wall portion (442a) facing rearward in the front-rear direction of the seat, the frame member is positioned between the front wall portion and the rear wall portion, and an insertion hole (451) for passing the connecting portion is formed in the rear wall portion, and the insertion hole may be positioned to overlap the through hole when viewed from the front-rear direction of the seat.

[0081] (Note 4) The vehicle seat described in Appendix 3, wherein the vertical length (L2) of the insertion hole may be smaller than the vertical length (L1) of the through hole.

[0082] (Note 5) The vehicle seat described in Appendix 2 further includes a frame member having a projection (421) that protrudes toward the cover member, and the cover member having a receiving portion (448) that engages with the projection.

[0083] (Note 6) The vehicle seat described in Appendix 5, wherein the protrusion has a plurality of convex portions (422) and a concave portion (423) formed between the convex portions, and the protrusion may engage with the receiving portion at the concave portion.

[0084] (Note 7) The vehicle seat described in Appendix 5 may have a dimension (W1) of the protruding portion in the seat width direction that is greater than the dimension (W2) of the receiving portion in the seat width direction.

[0085] (Note 8) The vehicle seat described in Appendix 5, wherein the cover member has a first surface (446) on which the receiving portion is provided and a second surface (447) opposite to the first surface, the receiving portion protrudes from the first surface, and the second surface may have a convex portion (450) that protrudes in the direction opposite to the direction in which the receiving portion protrudes.

[0086] (Note 9) A vehicle seat as described in any one of appendices 2 to 4, further comprising an airbag (50), wherein the protruding portion has a protruding surface (415) that supports the occupant's head, and the rear end of the airbag is located behind the protruding surface in the front-rear direction of the seat.

[0087] (Note 10) A method for manufacturing a vehicle seat according to the present disclosure comprises a seat back frame and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises a frame member supported by the seat back frame and a cover member covering the frame member and having a front wall portion facing forward in the seat front-rear direction, the cover member having a through hole in the front wall portion, and the frame member being positioned to overlap with the through hole when viewed from the seat front-rear direction, the method for manufacturing a vehicle seat comprises a first step (S20) of attaching the cover member to the frame member and a second step (S40) of attaching the headrest to the seat back frame after the first step.

[0088] Furthermore, the present invention is not limited to the disclosure described above, and can take various configurations without departing from the spirit of the invention. [Explanation of symbols]

[0089] 10...Vehicle seat 20...Seat back 22...Seat back frame 40...Headrest 41...Frame member 43...Joint 44...Cover component 50...Airbag 413...Protrusion part 415...Protrusion surface 421...Convex part 422...Convex portion 423...Concave part 441a...Front wall part 442a...Rear wall part 443...Through hole 446...First side 447...Second side 448...Receiving part 450...Convex part 451... Insertion hole

Claims

1. A vehicle seat comprising a seat back frame and a headrest attached to the upper part of the seat back frame, The aforementioned headrest is A frame member supported by the aforementioned seat back frame, The frame member is covered by a cover member having a front wall portion that faces forward in the front-rear direction of the seat, The cover member has a through hole in the front wall portion, A vehicle seat in which, when viewed from the front-to-rear direction of the seat, the frame member is positioned to overlap with the through-hole.

2. A vehicle seat according to claim 1, wherein the frame member has a protruding portion that passes through the through hole and protrudes forward from the front wall portion of the cover member.

3. A vehicle seat according to claim 2, further comprising a connecting portion joined to the rear surface of the protruding portion and for supporting the frame member on the seat back frame, The cover member has a rear wall portion facing backward in the front-rear direction of the seat, The frame member is positioned between the front wall and the rear wall. An insertion hole is formed in the rear wall portion for passing the connecting portion. A vehicle seat wherein, when viewed from the front-to-back direction of the seat, the insertion hole is positioned to overlap with the through hole.

4. A vehicle seat according to claim 3, wherein the vertical length of the insertion hole is smaller than the vertical length of the through hole.

5. A vehicle seat according to claim 2, further, The frame member has a protrusion that extends toward the cover member, The cover member is a vehicle seat having a receiving portion that engages with the protrusion.

6. A vehicle seat according to claim 5, The aforementioned protrusion has a plurality of convex portions and concave portions formed between the convex portions, The aforementioned convex portion engages with the receiving portion in the concave portion, and is a seat for a vehicle.

7. A vehicle seat according to claim 5, wherein the dimension of the protruding portion in the seat width direction is greater than the dimension of the receiving portion in the seat width direction.

8. A vehicle seat according to claim 5, The cover member has a first surface on which the receiving portion is provided, and a second surface opposite to the first surface. The receiving portion protrudes from the first surface, A seat for a vehicle, wherein the second surface has a convex portion that protrudes in the opposite direction to the protruding direction of the receiving portion.

9. A vehicle seat according to any one of claims 2 to 4, Furthermore, it is equipped with an airbag. The aforementioned projection has a protruding surface that supports the occupant's head. A vehicle seat wherein the rear end of the airbag is located behind the protruding surface in the front-to-rear direction of the seat.

10. A method for manufacturing a vehicle seat comprising a seat back frame and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises a frame member supported by the seat back frame and a cover member covering the frame member and having a front wall portion facing forward in the seat front-rear direction, the cover member having a through hole in the front wall portion, and the frame member being positioned so as viewed from the seat front-rear direction that it overlaps with the through hole, The first step is to attach the cover member to the frame member, A method for manufacturing a vehicle seat, comprising the second step of attaching the headrest to the seat back frame after the first step.

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