Vehicle seat and method for manufacturing a vehicle seat

Abstract

This distributes the stress acting on the frame where electrical components are mounted. [Solution] A seat 1 comprising a seat back 3 that supports the upper body of the sitter and a headrest 4 that supports the head, wherein the seat back 3 comprises a seat back frame 30 and a speaker system 6 attached to the seat back frame 30. The seat back frame 30 has a frame body 37, a first reinforcing part 38 that reinforces the frame body 37, and a headrest holding part 7 attached to the frame body 37 and holding the headrest 4. The speaker system 6 comprises a speaker device 60 and a wiring part 61 connected to the speaker device 60, and the speaker device 60 is fixed to the first reinforcing part 38 and the headrest holding part 7, respectively.

Description

Technical Field

[0001] The present invention relates to a vehicle seat to which electrical components are attached and a method for manufacturing the vehicle seat.

Background Art

[0002] In recent years, vehicle seats to which various electrical components are integrally attached have been known for the purpose of improving convenience and comfort during seating (see, for example, Patent Document 1). The vehicle seat described in Patent Document 1 attaches a speaker system to a seat back that supports the back of a seated person and outputs sound from behind the seated person toward the seated person.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when attempting to further improve convenience and comfort during seating, the number of electrical components increases, and the total weight of the electrical components increases. When the total weight of the electrical components increases, it becomes difficult to disperse the stress acting on the frame portion to which the electrical components are attached.

Means for Solving the Problems

[0005] One aspect of the present invention is a vehicle seat including a seat back that supports the upper body of a seated person and a headrest that supports the head. The seat back includes a frame portion and electrical components attached to the frame portion. The frame portion has a frame body, a reinforcing portion that reinforces the frame body, and a holding portion that is attached to the frame body and holds the headrest. The electrical components have an electrical component body and a wiring portion connected to the electrical component body. The electrical component body is fixed to each of the reinforcing portion and the holding portion. [Effects of the Invention]

[0006] According to the present invention, the stress acting on the frame portion to which electrical components are attached can be distributed. [Brief explanation of the drawing]

[0007] [Figure 1] A front view of a sheet according to an embodiment of the present invention. [Figure 2] A perspective view of the seat with the upholstery, seat back pad, and garnish removed from the seat back. [Figure 3] An exploded perspective view of the seat with the upholstery and seat back pad removed from the seat back. [Figure 4] A perspective view from the rear of the first reinforcing section that reinforces the main frame. [Figure 5] Perspective view of the headrest retaining section and garnish mounting section. [Figure 6] A perspective view of the surface grille that makes up the garnish. [Figure 7A] A perspective view of the grille guide, which makes up the garnish, seen from the front. [Figure 7B] Figure 7A is a perspective view of the grille guide seen from the rear. [Figure 8A] A perspective view of the inner garnish, which makes up the garnish, as seen from the front. [Figure 8B] Figure 8A is a perspective view of the inner garnish, seen from the rear. [Figure 9] Front view of the speaker system fixed to the seat back frame. [Figure 10A] A view from above of the first extension of the rear casing that secures the speaker device. [Figure 10B] An enlarged view of the first extension shown in Figure 10A. [Figure 11A] A cross-sectional view showing the inner garnish with the grille guide and outer grille attached. [Figure 11B]A cross-sectional view showing the grille guide and exterior grille attached to the inner garnish. [Modes for carrying out the invention]

[0008] Hereinafter, an embodiment of the present invention will be described with reference to Figures 1 to 11B. The vehicle seat according to this embodiment is a seat in which a garnish and a speaker system (electrical components) are integrally attached to the seat back, and can be used as a seat installed in various vehicles such as aircraft, trains, ships, and automobiles. In the following, as an example of a vehicle seat, a seat installed in an automobile, in particular a rear seat (hereinafter simply referred to as a seat) that constitutes the rear seat of an automobile will be used for explanation. Furthermore, in the following, the front-to-back direction, left-to-right direction (width direction), and up-and-down direction (height direction) will be defined based on the occupant (seatee) seated in the seat, and the configuration of each part will be described according to this definition.

[0009] <Overall structure of the sheet> Figure 1 is a front view of seat 1 according to an embodiment of the present invention. Note that Figure 1 only shows the right seat (right side) of the rear seat which can seat three people, and omits the center seat (center) and left seat (left side). Therefore, in the following description, the right seat of the rear seat will be referred to as seat 1. As shown in Figure 1, seat 1 includes a seat cushion 2 that supports the occupant's buttocks, a seat back 3 that supports the occupant's upper body (waist and back), and a headrest 4 that supports the occupant's head.

[0010] The seat cushion 2 is constructed by attaching a seat cushion pad 21 made of cushioning material such as urethane foam to a seat cushion frame 20 that forms the frame, and then covering the outside with a surface material 22 made of synthetic leather or fabric, and is supported so as to be able to slide in the front-rear direction by a sliding mechanism (not shown) provided on the floor of the vehicle.

[0011] The seat back 3 is configured by attaching a seat back pad 31 made of a cushion material such as urethane foam to a seat back frame (frame portion) 30 that forms a skeleton, and further covering the outside thereof with a skin material 32 made of synthetic leather, fabric, or the like, and is rotatably supported by a reclining mechanism (not shown) on the seat cushion 2.

[0012] In the seat 1, the seat back 3 has a garnish 5 provided at both shoulder openings of the seated occupant, and a speaker system 6 attached inside the seat back 3 so as to face the garnish 5. The garnish 5 constitutes the speaker grill of the speaker system 6, and the speaker system 6 outputs sound from both shoulder openings of the seated occupant through the garnish 5. The specific configuration of the seat back 3 having the garnish 5 and the speaker system 6 will be described in detail later.

[0013] The headrest 4 does not have a frame that forms a skeleton like the seat cushion 2 or the seat back 3. The headrest 4 is configured by filling a cushion pad (headrest body) 41 made of a cushion material such as urethane foam inside a skin material (headrest body) 42 made of synthetic leather, fabric, or the like, and further disposing a headrest pillar 40 therein. The headrest 4 is held at the upper part of the seat back 3 through the headrest pillar 40. In the seat 1, the headrest 4 is provided in a state of being held at the upper part of the seat back 3 through the headrest pillar 40 so that at least a part thereof overlaps with the garnish 5. In other words, at least a part of the headrest 4 is provided so as to overlap with a part of the speaker system 6 in the front-rear direction.

[0014] The headrest pillar 40 is formed by bending a metal rod-shaped member and has a pair of leg portions 40a, 40a held by the seat back frame 30. The headrest pillar 40 is sandwiched from the front-rear direction between a front headrest cover 43 and a rear headrest cover 44 that are abutted and engaged with each other, and is protected thereby (see FIGS. 2 and 3 described later).

[0015] <Seat back> FIG. 2 is a perspective view of the seat 1 with the seat back pad 31, the skin material 32, and the garnish 5 removed from the seat back 3, and FIG. 3 is an exploded perspective view of the seat 1 with the skin material 32 and the seat back pad 31 removed from the seat back 3.

[0016] As shown in FIGS. 2 and 3, the seat back 3 includes a metal seat back frame 30 that forms the skeleton of the seat back 3, a front plate 33 made of synthetic resin provided on the front surface of the seat back frame 30, a back plate 34 made of synthetic resin provided on the back surface of the seat back frame 30, a rear cover 35 made of synthetic resin provided above the seat back frame 30 and the back plate 34, a belt retractor 36 in which a seat belt is housed, a garnish 5 attached to the seat back frame 30, and a speaker system 6 attached to the seat back frame 30 so as to face the garnish 5. In FIG. 2, the description of the front plate 33 and the rear cover 35 is omitted.

[0017] The seat back frame 30 includes a frame body 37, a first reinforcing portion (reinforcing portion) 38 and a second reinforcing portion 39 that reinforce the frame body 37, a headrest holding portion (holding portion) 7 attached to the frame body 37 and holding the headrest 4, and a garnish attachment portion (attachment portion) 8 attached to the frame body 37 and to which the garnish 5 can be attached.

[0018] The frame body 37 is formed in a substantially rectangular plate shape facing in the front-rear direction, and has a first opening 37a provided in the upper left, a second opening 37b provided in the lower left, and a third opening 37c provided in the substantially central portion in the left-right direction, and a plurality of ribs (not shown). The frame body 37 can be made lighter by providing the substantially rectangular first to third openings 37a to 37c, and each part is reinforced by providing a plurality of ribs. The plurality of ribs include those formed in an uneven shape on the frame body 37.

[0019] The first reinforcing part 38 is joined to the frame body 37 on the right side of the third opening 37c of the frame body 37 and below the speaker system 6, thereby reinforcing the frame body 37 on the right side of the third opening 37c of the frame body 37 and below the speaker system 6.

[0020] Figure 4 is a rearward perspective view of the first reinforcing portion 38 that reinforces the frame body 37. As shown in Figure 4, the first reinforcing portion 38 has a front portion 38a formed in the shape of a substantially rectangular plate facing the front-rear direction, a first extension portion 38b extending rearward from the left end of the front portion 38a approximately in the vertical center, a second extension portion 38c extending rearward from the left end lower than the first extension portion 38b, a third extension portion 38d extending rearward from the right end slightly above the second extension portion 38c, a fourth extension portion 38e extending rearward from the right end at approximately the same height as the first extension portion 38b, a pair of sixth extension portions 38g, 38g extending to both sides in the left-right direction from the upper end, and a reinforcing means 38h provided between the pair of sixth extension portions 38g, 38g.

[0021] The front portion 38a is formed to be in contact with the frame body 37 and is provided with a plurality of joint portions 38a1 that are joined to the frame body 37 while in contact with it. Each of the plurality of joint portions 38a1 is composed of a through hole, and the front portion 38a is joined to the frame body 37 by various welding methods such as arc welding through the through hole. Figure 2 shows a plurality of weld beads 38a2 formed on each of the plurality of joint portions 38a1 by welding. The front portion 38a also has a fifth extension portion 38f that extends to the right (outward in the left-right direction) from the right end above the fourth extension portion 38e.

[0022] Each of the first to third extensions 38b, 38c, and 38d has a support portion (second support portion, third support portion) 38b1, 38c1, and 38d1 capable of supporting the wiring portion 61 of the speaker system 6. Each of the support portions 38b1, 38c1, and 38d1 is composed of a through hole and is formed to allow a clip 65 that supports the wiring portion 61 to be locked into it. Each of the support portions 38b1, 38c1, and 38d1 is formed to allow the clip 65 to be locked into it so that the wiring portion 61 extends in the vertical direction.

[0023] The fourth extension 38e is formed to be in contact with the frame body 37, and is provided with a joining portion 38e1 for joining while in contact with the frame body 37. The joining portion 38e1 is made up of a through hole, and the fourth extension 38e is joined to the frame body 37 through the through hole by various welding methods such as arc welding.

[0024] The fifth extension 38f is located above the upper joint 38a1 and has a support portion (first support portion) 38f1 capable of supporting the wiring portion 61 of the speaker system 6. The support portion 38f1 is made up of a through hole and is formed to be able to lock a clip 65 that supports the wiring portion 61. The support portion 38f1 locks the clip 65 so that its extension direction is different from that of the wiring portion 61 supported by each of the support portions 38b1, 38c1, and 38d1. Specifically, the support portion 38f1 is formed to be able to lock the clip 65 so that the wiring portion 61 extends in the left-right direction.

[0025] A pair of sixth extensions 38g, 38g are formed to be in contact with the frame body 37, and each of the pair of sixth extensions 38g, 38g is provided with a fixing portion 38g1 that can be fixed to the frame body 37. The fixing portion 38g1 is made up of a through hole and is fixed to the frame body 37 by a bolt and nut 10 through a through hole (not shown) formed in the frame body 37. The bolt and nut 10 also fix the speaker system 6 to the frame body 37 via the fixing portion 38g1 of the sixth extension 38g and the through hole (not shown) in the frame body 37.

[0026] The reinforcing means 38h is formed in a convex shape that protrudes toward the seating surface (forward), and has a contact portion 38h1 that can contact the lower surface of the speaker system 6 when the first reinforcing portion 38 is joined to the frame body 37. By providing the contact portion 38h1, for example, the positioning of the speaker system 6 when fixing the speaker system 6 to the frame body 37 with bolts and nuts 10 becomes easier. Note that the reinforcing means 38h may be configured with, for example, a bead or flange instead of a convex shape that protrudes forward.

[0027] The second reinforcing portion 39 is provided extending diagonally from below the first opening 37a and above the second opening 37b of the frame body 37 towards the lower right end below the third opening 37c, and is joined to the frame body 37 in this state. In other words, the second reinforcing portion 39 reinforces the frame body 37 diagonally from between the first opening 37a and the second opening 37b, avoiding the third opening 37c.

[0028] The second reinforcing portion 39 is formed in a plate shape that can abut against the frame body 37, and is provided with a plurality of joint portions 39a1 that are joined to the frame body 37 while in contact with it. Each of the plurality of joint portions 39a1 is composed of a through hole, and the second reinforcing portion 39 is joined to the frame body 37 by various welding methods such as arc welding through the through hole. Figure 2 shows a plurality of weld beads 39a2 formed on each of the plurality of joint portions 39a1 by welding. At least a portion of the plurality of joint portions 39a1, i.e., the plurality of weld beads 39a2, is provided along the extending direction of the second reinforcing portion 39.

[0029] The headrest retaining portion 7 and the garnish mounting portion 8 are attached to the frame body 37 at approximately the center in the left-right direction at the upper end of the frame body 37, so as to overlap in the front-rear direction. Specifically, the headrest retaining portion 7 is located behind the garnish mounting portion 8, and the support bar 37d, which is joined to the frame body 37, is located behind the headrest retaining portion 7. In this state, the headrest retaining portion 7 and the garnish mounting portion 8 are attached to the frame body 37 via the support bar 37d. The support bar 37d is formed by bending a rod-shaped member and is joined to the frame body 37 in an inverted U shape.

[0030] Figure 5 is a perspective view of the headrest retaining portion 7 and the garnish mounting portion 8. As shown in Figure 5, the headrest retaining portion 7 comprises a rectangular plate-shaped retaining portion body 70 extending in the left-right direction, a first extension portion 71 extending rearward from the upper end of the retaining portion body 70, a second extension portion 72 extending downward from the lower end of the retaining portion body 70, and a pair of left and right pillar guide portions 73, 73 provided on the front surface of the retaining portion body 70 to support a pair of legs 40a, 40a of the headrest pillar 40.

[0031] The main body of the retaining part 70 has fixing parts 70a, 70a on both the left and right sides, to which the speaker system 6 can be fixed. The fixing parts 70a are made up of through holes and are formed so that the speaker system 6 can be fixed to the main body of the retaining part 70 by bolts and nuts. The first extension part 71 is provided extending rearward from approximately the center of the main body of the retaining part 70 in the left and right direction so as to abut against the upper surface of the support bar 37d, and is joined to the upper surface of the support bar 37d by various welding methods such as arc welding. The second extension part 72 is formed so as to abut against the frame body 37 and has a fixing part 72a that can be fixed to the frame body 37. The fixing part 72a is made up of through holes and is formed so that the headrest retaining part 7 can be fixed to the frame body 37 by bolts and nuts 11 through holes (not shown) formed in the frame body 37. Furthermore, the bolts and nuts 11 also fix the garnish mounting portion 8 to the frame body 37 via the fixing portion 72a of the second extension portion 72 and through holes (not shown) in the frame body 37. The headrest holding portion 7 is also joined to the frame body 37 by welding on both sides in the left-right direction of the second extension portion 72, as shown by the weld beads 74, 74 in Figure 5.

[0032] The left and right pair of pillar guide portions 73, 73 are formed in a substantially cylindrical shape through which the pair of leg portions 40a, 40a can be inserted, and are provided at a predetermined distance apart in the approximate center of the holding portion body 70 in the left-right direction. The left and right pair of pillar guide portions 73, 73 are joined to the holding portion body 70 by welding in front of the holding portion body 70, as shown by the weld beads 75, 75 in Figure 5.

[0033] The garnish mounting portion 8 comprises a mounting portion body 80 formed to be fixable to the headrest holding portion 7, and a pair of left and right wire portions (wires) 81R, 81L. The mounting portion body 80 is formed in the shape of a rectangular plate extending in the vertical direction, which can be positioned between a pair of pillar guide portions 73, 73, and has a fixing portion 81 at a position opposite to the fixing portion 72a of the second extension portion 72. The fixing portion 81 is made up of through holes and is formed to be fixable to the frame body 37 by bolts and nuts 11 via the fixing portion 72a of the second extension portion 72 and through holes (not shown) in the frame body 37.

[0034] Each of the pair of left and right wire sections 81R and 81L is formed by bending a single wire. As shown in the weld bead 87 in Figure 5, one end 82 is welded to the upper part of the mounting section body 80, and the other end 83 is welded to approximately the center of the mounting section body 80 in the vertical direction. Each of the pair of left and right wire sections 81R and 81L also has an upper wire 84 that can engage with the upper part of the garnish 5, a side wire 85 that can engage with the side of the garnish 5, and a lower wire 86 that can engage with the lower part of the garnish 5. The upper wire 84 and lower wire 86 extend in the left-right direction, and the side wire 85 extends in the vertical direction.

[0035] The front plate 33 is attached to the front of the seat back frame 30 and covers and protects a part of the seat back frame 30 and a part of the components supported by the seat back frame 30. The front plate 33, together with the seat back pad 31, seat back frame, and rear cover 35, etc., constitutes the outer shape of the seat back 3.

[0036] The back plate 34 is attached to the back of the seat back frame 30 and covers and protects a part of the seat back frame 30 and a part of the components supported by the seat back frame 30. The back plate 34 has an opening 34a located at a position corresponding to the first opening 37a of the frame body 37, and a covering portion 34b that covers the second opening 37b of the frame body 37, and also covers a part of the third opening 37c of the frame body 37. The back plate 34 also mitigates impacts acting on the seat back 3 from the rear, for example, from the trunk located behind the seat back 3.

[0037] The rear cover 35 is attached to the upper part of the seat back frame 30 and back plate 34, and covers and protects the upper part of the seat back frame 30 and back plate 34, as well as the parts provided on these upper parts. For example, it protects the headrest retaining part 7 and part of the garnish mounting part 8 from above. The rear cover 35, together with the seat back pad 31 and front plate 33, etc., constitutes the outer shape of the seat back 3.

[0038] The belt retractor 36 is attached to the seat back frame 30 via a retractor protective cover 36a positioned in the first opening 37a of the frame body 37 and the opening 34a of the back plate 34. A seat belt (not shown) housed in the belt retractor 36 is used via a shoulder anchor 36b provided on the upper left side of the seat back frame 30.

[0039] The garnish 5 comprises a synthetic resin surface grille (surface member) 50 that constitutes the surface, a synthetic resin grille guide (second garnish) 51 that can engage with the surface grille 50, and a synthetic resin inner garnish (first garnish) 52 that can engage with the grille guide 51, and is formed to be attachable to a pair of left and right wire sections 81R, 81L of the garnish mounting section 8. The grille guide 51 and the inner garnish 52 are configured to be fitted into the pair of left and right wire sections 81R, 81L from the front and rear, and to engage by abutting against each other, and the surface grille 50 is configured to engage by abutting against the grille guide 51.

[0040] Figure 6 is a perspective view of the surface grille 50 that constitutes the garnish 5. As shown in Figure 6, the surface grille 50 comprises a grille body (surface base) 501 extending in the left-right direction and a frame portion 502 provided on the outer edge of the grille body 501. The grille body 501 is provided so as to be able to cover the left and right pair of wire portions 81R, 81L of the garnish mounting portion 8 and is formed in a mesh shape that penetrates in the front-rear direction. The frame portion 502 is provided along the outer edge of the grille body 501 and has a plurality of protrusions (surface fixing portions) 503 that project backward toward the rear on the back surface (rear side) 501R side of the grille body 501. The plurality of protrusions 503 are provided at predetermined intervals and each of the plurality of protrusions 503 is provided with a locking claw 504 that can lock the surface grille 50 to the grille guide 51.

[0041] Figure 7A is a perspective view of the grille guide 51, which constitutes the garnish 5, as seen from the front, and Figure 7B is a perspective view of the grille guide 51 of Figure 7A as seen from the rear. As shown in Figures 7A and 7B, the grille guide 51 is formed to have an outer shape substantially the same as that of the surface grille 50, and is formed to be able to engage with the surface grille 50 by abutting against it. Specifically, the grille guide 51 comprises a guide body 511 that extends in the left-right direction and has substantially the same shape as the grille body 501, and a frame portion 512 provided on the outer edge of the guide body 511. The guide body 511 has honeycomb portions 513, 513 provided on both sides in the left-right direction. The honeycomb portion 513 is composed of a plurality of honeycombs that penetrate in the front-rear direction and is provided at a position facing the speaker unit 62 of the speaker system 6, which will be described later.

[0042] The front surface (front side) 511F of the guide body 511 is provided with ribs 514 arranged in a grid pattern, and the guide body 511 contacts the back surface 501R of the grill body 501 via the grid-like ribs 514. In addition, the back surface (second bottom) 511R of the guide body 511 is provided with a plurality of projections (second vertical wall portions) 515 that protrude toward the rear. The plurality of projections 515 include a pair of first projections 515a, 515a provided on the upper part of the guide body 511, a pair of second projections 515b, 515b provided on both sides in the left-right direction, a pair of third projections 515c, 515c provided on the lower part, and a pair of fourth projections 515d, 515d provided approximately in the center in the width direction. Each of the pair of first to fourth protrusions 515a, 515a to 515d, and 515d is provided with a locking claw 516 that can lock the grille guide 51 to the inner garnish 52.

[0043] The frame portion 512 is provided along the outer edge of the guide body 511 and has a plurality of through holes 517 that can pass through a plurality of projections 503 of the grill body 501. The plurality of through holes 517 are provided at positions corresponding to the plurality of projections 503 of the surface grill 50 when the surface grill 50 is abutted against the grill guide 51, and are formed so that the locking claws 504 of the projections 503 that pass through the through holes 517 are locked to the back surface 511R of the guide body 511.

[0044] Figure 8A is a perspective view of the inner garnish 52, which constitutes the garnish 5, as seen from the front, and Figure 8B is a perspective view of the inner garnish 52 of Figure 8A as seen from the rear. As shown in Figures 8A and 8B, the inner garnish 52 is formed to have an outer shape substantially the same as that of the grille guide 51, and is formed to engage with the grille guide 51 by abutting against it. Specifically, the inner garnish 52 extends in the left-right direction and comprises an inner body 521 which has substantially the same shape as the guide body 511, and a frame portion 522 provided on the outer edge of the inner body 521. The inner body 521 has openings 523, 523 provided on both sides in the left-right direction, and the openings 523, 523 are positioned opposite the honeycomb portions 513, 513 of the guide body 511, and also opposite the speaker unit 62 of the speaker system 6.

[0045] Furthermore, the inner body 521 has a plurality of through holes 524 that can pass through a plurality of protrusions 515 of the guide body 511. Specifically, the plurality of through holes 524 include a pair of first through holes 524a, 524a corresponding to a pair of first protrusions 515a, 515a of the guide body 511, a pair of second through holes 524b, 524b corresponding to a pair of second protrusions 515b, 515b, a pair of third through holes 524c, 524c corresponding to a pair of third protrusions 515c, 515c, and a pair of fourth through holes 524d, 524d corresponding to a pair of fourth protrusions 515d, 515d. The pair of first to fourth through holes 524a, 524a to 524d, and 524d are formed so that when the grille guide 51 is abutted against the inner garnish, the locking claws 516 of the pair of first to fourth projections 515a, 515a to 515d, and 515d of the guide body 511 are locked against the back surface 521R of the inner body 521.

[0046] Furthermore, the back surface 521R of the inner body 521 is provided with a plurality of recessed portions (first recesses) 525 at positions corresponding to the plurality of through holes 524. Specifically, the plurality of recessed portions 525 include a pair of first recessed portions 525a, 525a corresponding to a pair of first through holes 524a, 524a, a pair of second recessed portions 525b, 525b corresponding to a pair of second through holes 524b, 524b, and a pair of third recessed portions 525c, 525c corresponding to a pair of third through holes 524c, 524c.

[0047] Each of the pair of first to third concave portions 525a, 525a to 525c, and 525c has a bottom portion (first bottom portion) 526 provided on the back surface 521R, a vertical wall portion (first vertical wall portion) 527 rising from the bottom portion 526, and an extension portion (first extension portion) 528 extending from the vertical wall portion 527. The space enclosed by the bottom portion 526, the vertical wall portion 527, and the extension portion 528 is formed to allow the left and right pairs of wire portions 81R and 81L of the garnish mounting portion 8 to be positioned there. For example, the space enclosed by the bottom 526, vertical wall 527, and extension 528 of the pair of first concave portions 525a, 525a can enclose the upper wires 84 of the left and right pair of wire portions 81R, 81L; the space enclosed by the bottom 526, vertical wall 527, and extension 528 of the pair of second concave portions 525b, 525b can enclose the side wires 85; and the space enclosed by the bottom 526, vertical wall 527, and extension 528 of the pair of third concave portions 525c, 525c can enclose the lower wire 86.

[0048] Furthermore, the bottom 526 of each of the pair of first to third concave sections 525a, 525a to 525c, and 525c is provided with a relief section 529 that is recessed in the thickness direction. By providing the relief section 529 at the bottom 526, it becomes easier to guide the pair of left and right wire sections 81R and 81L into each of the pair of first to third concave sections 525a, 525a to 525c, and 525c. In addition, the tips of the extensions 528 of each of the pair of first to third concave sections 525a, 525a to 525c, and 525c are formed to open away from the bottom 526. By forming the tips of the extensions 528 to open away from the bottom 526, it becomes easier to guide the pair of left and right wire sections 81R and 81L into each of the pair of first to third concave sections 525a, 525a to 525c, and 525c.

[0049] Figure 9 is a front view of the speaker system 6 fixed to the seat back frame 30. As shown in Figure 9, the speaker system 6 consists of a pair of left and right speaker systems 6R and 6L, each of which comprises a speaker device (electrical component body) 60 and a wiring section 61 connected to the speaker device 60.

[0050] The speaker device 60 includes a speaker unit 62 that outputs sound, a speaker box 63 that supports the speaker unit 62, and a rear casing 64 that fixes the speaker box 63 to the seat back frame 30. A general cone-type speaker unit 62 can be used, so a detailed explanation is omitted here. The speaker box 63 supports the speaker unit 62 on its front side so that the speaker unit 62 faces the honeycomb portion 513 of the guide body 511 and the opening 523 of the inner body 521. Furthermore, the speaker box 63 is formed in a concave shape that recesses inward downward from this support portion, from the viewpoint of ease of sitting, etc. (see Figure 11A described later).

[0051] The rear casing 64 is joined to the rear side of the speaker box 63 and comprises a casing body 641 joined to the speaker box, a first extension 642 extending upward from the upper end of the casing body 641 approximately in the center in the left-right direction, and a pair of second extensions 643, 643 extending downward from the lower ends on both sides of the casing body 641 in the left-right direction.

[0052] Figure 10A is a view from above of the first extension 642 of the rear casing 64 that secures the speaker box 63, and Figure 10B is an enlarged view of the first extension 642 shown in Figure 10A. In addition to Figure 9, as shown in Figures 10A and 10B, the first extension 642 has a first fixing portion 642a which is formed by a through hole, and the first fixing portion 642a is provided opposite to the fixing portion 70a provided on the holding body 70 of the headrest holding portion 7. Since a pair of left and right pillar guide portions 73, 73 are provided on the front surface of the holding body 70 of the headrest holding portion 7, the first fixing portion 642a of the first extension 642 is provided at approximately the same height as the pair of left and right pillar guide portions 73, 73. Therefore, the rear casing 64 is fixed to the headrest holding portion 7 via the first fixing portion 642a of the first extension portion 642 at approximately the same height as the pair of left and right pillar guide portions 73, 73.

[0053] Each of the pair of second extensions 643, 643 has a second fixing portion 643a formed by a through hole, and the pair of second fixing portions 643a, 643a are provided opposite to the fixing portions 38g1, 38g1 of the pair of sixth extensions 38g, 38g provided on the first reinforcing portion 38. The lower end of the rear casing 64 is fixed to the frame body 37 and the first reinforcing portion 38 via the second fixing portions 643a, 643a of the pair of second extensions 643, 643. In other words, the lower end of the rear casing 64 is fixed so as to overlap with the frame body 37 and the first reinforcing portion 38 at the position where they overlap.

[0054] The wiring section 61 connects the speaker unit 62 to an amplifier (not shown), and inputs the audio signal output from the amplifier to the speaker unit 62. In seat 1, the wiring section 61 extends from below to above the seat back 3 and is fixed to the seat back frame 30 at multiple points via clips 65.

[0055] In sheet 1, the wiring section 61 is supported by the first reinforcing section 38 at multiple locations at different heights. Specifically, the wiring section 61 is supported via clips 65 so as to extend vertically at the first extension 38b and the third extension 38d of the first reinforcing section 38. Since the first extension 38b is provided at approximately the same height as the fourth extension 38e, the wiring section 61 is supported at the same height as the joint 38e1 of the fourth extension 38e.

[0056] Furthermore, the wiring section 61 is supported via a clip 65 so as to extend in the left-right direction at the fifth extension 38f of the first reinforcing section 38. Since the fifth extension 38f is located above the fourth extension 38e, the support portion 38f1 of the fifth extension 38f is located between the joint portion 38e1 of the fourth extension 38e and the speaker device 60. In addition, the joint portion 38e1 of the fourth extension 38e is located between the support portion 38d1 of the third extension 38d and the support portion 38f1 of the fifth extension 38f in the vertical direction, and between the support portion 38d1 of the first extension 38b and the support portion 38d1 of the third extension 38d in the left-right direction.

[0057] The seat back 3, configured as described above, is manufactured as follows. First, the first reinforcing part 38 and the second reinforcing part 39 are joined to the frame body 37 by welding or the like. Next, the garnish mounting part 8 and the headrest holding part 7 are fixed to the frame body 37 with bolts and nuts 11 and joined by welding or the like. This forms the seat back frame 30.

[0058] Next, the speaker system 6 is attached to the seat back frame 30. First, the lower end of the speaker device 60 is brought into contact with the contact portion 38h1 formed on the reinforcing means 38h of the first reinforcing portion 38 to position it. Then, the pair of second extensions 643, 643 of the rear casing 64 are fixed to the fixing portions 38g1, 38g1 of the pair of sixth extensions 38g, 38g of the first reinforcing portion 38 using bolts and nuts 10, 10. As a result, the speaker device 60 is attached to the seat back frame 30 so that it aligns with the position where the frame body 37 and the first reinforcing portion 38 overlap in the front-rear direction.

[0059] Next, the first extension 642 of the rear casing 64 is fixed to the fixing portion 70a of the headrest holding portion body 70 using bolts and nuts. As a result, the first extension 642 of the rear casing 64 is fixed between the pair of second extensions 643, 643 of the rear casing 64.

[0060] Next, the inner garnish 52 is attached to the left and right pair of wire sections 81R and 81L of the garnish mounting section 8. Specifically, the left and right pair of wire sections 81R and 81L of the garnish mounting section 8 are positioned in the space enclosed by the bottom 526, vertical wall section 527 and extension section 528 of the multiple recessed sections 525 of the inner garnish 52 by bending the vertical wall section 527 and extension section 528. At this time, a relief section 529 is provided at the bottom 526 of each of the multiple recessed sections 525 of the inner garnish 52, and the tip of the extension section 528 is formed to open away from the bottom 526, making it easier to guide the left and right pair of wire sections 81R and 81L to the pair of first to third recessed sections 525a, 525a to 525c, and 525c, respectively.

[0061] Next, the grille guide 51 and the exterior grille 50 are attached to the inner garnish 52. Figure 11A is a cross-sectional view showing the state in which the grille guide 51 and the exterior grille 50 are attached to the inner garnish 52, and Figure 11B is a cross-sectional view showing the state in which the grille guide 51 and the exterior grille 50 are attached to the inner garnish 52.

[0062] As shown in Figures 11A and 11B, first, a pair of projections 515, 515 formed on the back surface 511R of the guide body 511 of the grille guide 51 are passed through a pair of through holes 524, 524 formed in the inner body 521 of the inner garnish 52. This locks the grille guide 51 to the inner garnish 52. At this time, the pair of projections 515, 515 of the grille guide 51 are positioned in the open portions of the pair of concave portions 525, 525 of the inner garnish 52, and the outer circumferences of the upper wire 84, side wire 85, and lower wire 86 of the left and right pair of wire portions 81R, 81L are surrounded by the concave portions 525 and the projections 515. The projections 515 are formed so as not to come into contact with the extension portion 528 when the grille guide 51 is locked to the inner garnish 52, thereby suppressing the generation of abnormal noise due to contact between the projections 515 and the extension portion 528.

[0063] Next, the exterior grille 50 is abutted against the grille guide 51 and engaged with the grille guide 51. When the exterior grille 50 is abutted against the grille guide 51, the multiple protrusions 503 of the exterior grille 50 pass through the multiple through holes 517 of the grille guide 51, and the exterior grille 50 is locked to the grille guide 51. At this time, the tips of the multiple protrusions 503 of the exterior grille 50 are located between the back surface of the grille guide 51 and the front surface of the inner garnish 52. In addition, since the front surface 511F of the guide body 511 of the grille guide 51 is provided with ribs 514 arranged in a grid pattern, the grille body 501 and the guide body 511 come into contact via the ribs 514.

[0064] Next, the belt retractor 36 is attached via the retractor protection cover 36a, and the remaining parts such as the front plate 33, back plate 34, and rear cover 35 are attached. Finally, the seat back pad 31 is attached, and the outer covering material 32 is then placed over it to form the seat back 3.

[0065] This embodiment can provide the following effects and advantages. (1) The seat 1 according to this embodiment includes a seat back 3 that supports the upper body of the sitter and a headrest 4 that supports the head. The seat back 3 includes a seat back frame 30 and a speaker system 6 attached to the seat back frame 30. The seat back frame 30 has a frame body 37, a first reinforcing part 38 that reinforces the frame body 37, and a headrest holding part 7 that is attached to the frame body 37 and holds the headrest 4. The speaker system 6 has a speaker device 60 and a wiring part 61 connected to the speaker device 60, and the speaker device 60 is fixed to the first reinforcing part 38 and the headrest holding part 7, respectively.

[0066] This configuration allows the speaker device 60 to be supported by the first reinforcement portion 38 and the headrest holding portion 7, thereby efficiently distributing the stress acting on the seat back frame 30 to which the speaker system 6 is attached without increasing the number of parts.

[0067] (2) The headrest 4 has a surface material 42 filled with a cushion pad 41 and a headrest pillar 40 extending from the surface material 42 filled with the cushion pad 41. The headrest holding part 7 has a pillar guide part 73 that supports the headrest pillar 40, and the speaker device 60 fixed to the headrest holding part 7 is fixed at the same height as the pillar guide part 73. With this configuration, the speaker device 60 is fixed at the headrest holding part 7 which is at the same height as the highly rigid pillar guide part 73, so that the stress acting on the seat back frame 30 to which the speaker system 6 is attached can be efficiently distributed.

[0068] (3) The speaker device 60, which is fixed to the headrest retaining portion 7, is fixed behind the pillar guide portion 73. With this configuration, the pillar guide portion 73 is located in front of the speaker device 60, so that, for example, the load does not concentrate on the mounting portion of the speaker device 60 when subjected to a load from the front.

[0069] (4) The speaker device 60 fixed to the first reinforcement part 38 is fixed at a different position in the left-right direction from the position where it is fixed to the headrest holding part 7. This configuration makes it possible to improve the mounting strength of the speaker device 60. (5) The speaker device 60 is fixed to the first reinforcing portion 38 by the second fixing portions 643a of each of the pair of second extensions 643, 643, and the speaker device 60 fixed to the headrest holding portion 7 is fixed between the second fixing portions 643a, 643a of each of the second extensions 643, 643. This configuration improves the mounting strength of the speaker device 60. (6) The first reinforcing portion 38 has a pair of sixth extensions 38g, 38g to which the speaker device 60 can be fixed, and a reinforcing means 38h provided between the pair of sixth extensions 38g, 38g. This configuration makes it possible to improve the rigidity of the frame body 37 by the first reinforcing portion 38. (7) The reinforcing means 38h has a shape that protrudes toward the seating surface and is formed to be able to contact at least a part of the speaker device 60. This configuration further improves the rigidity of the frame body 37 by the first reinforcing part 38 and makes it easier to position the speaker device 60 when mounting it. (8) The headrest 4 is held to the seatback 3 such that at least a portion of it overlaps with the speaker device 60 in the front-to-back direction. This configuration allows the headrest 4 to be positioned compactly in the height direction. (9) A method for manufacturing a seat 1 comprising a seat back 3 having a seat back frame 30 and a speaker system 6 attached to the seat back frame 30, and a headrest 4, wherein the seat back frame 30 has a frame body 37, a first reinforcing part 38 that reinforces the frame body 37, and a headrest holding part 7 attached to the frame body 37 and holding the headrest 4, and the speaker system 6 has a speaker device 60 and a wiring part 61 connected to the speaker device 60, wherein the method for manufacturing a seat 1 comprises fixing the speaker device 60 to the first reinforcing part 38 and the headrest holding part 7, respectively.

[0070] This configuration allows the speaker device 60 to be supported by the first reinforcement portion 38 and the headrest holding portion 7, thereby efficiently distributing the stress acting on the seat back frame 30 to which the speaker system 6 is attached without increasing the number of parts.

[0071] The above embodiment can be modified into various forms.

[0072] For example, in the above embodiment, a speaker unit was used as an electrical component, but the electrical component is not limited to this. The electrical component may also be a device that can improve the convenience and comfort of the occupants, such as a massage device or a microphone device that inputs commands to various equipment in the vehicle by voice.

[0073] Furthermore, although the above embodiment described the vehicle seat using the rear seat of an automobile, the vehicle seat is not limited to this. The vehicle seat may be, for example, the driver's seat or passenger seat that make up the front seats of an automobile, or a seat installed in a vehicle other than an automobile.

[0074] The above description is merely an example, and the present invention is not limited by the embodiments and modifications described above, as long as the features of the present invention are not impaired. It is also possible to arbitrarily combine one or more of the above embodiments and modifications, and to combine modifications with each other. [Explanation of symbols]

[0075] 1 Seat (vehicle seat), 2 Seat cushion, 3 Seat back, 4 Headrest, 5 Garnish, 6 Speaker system (electrical component), 7 Headrest holder (holding part), 8 Garnish mounting part (mounting part), 30 Seat back frame (frame part), 37 Frame body, 38 First reinforcement part (reinforcement part), 51 Grille guide (second garnish), 52 Inner garnish (first garnish), 60 Speaker device (electrical component body), 61 Wiring section, 81R, 81L Wire section

Claims

1. In a vehicle seat comprising a seatback that supports the upper body of the occupant and a headrest that supports the head, The seat back comprises a frame and electrical components attached to the frame, The frame portion comprises a frame body, a reinforcing portion that reinforces the frame body, and a holding portion that is attached to the frame body and holds the headrest. The aforementioned electrical component comprises an electrical component body and a wiring section connected to the electrical component body. The vehicle seat is characterized in that the electrical component body is fixed to the reinforcing portion and the holding portion, respectively.

2. In the vehicle seat according to claim 1, The headrest comprises a headrest body and a headrest pillar extending from the headrest body. The retaining portion has a pillar guide portion that supports the headrest pillar, A vehicle seat characterized in that the main body of the electrical component fixed to the holding portion is fixed at the same height as the pillar guide portion.

3. In the vehicle seat according to claim 2, A vehicle seat characterized in that the main body of the electrical component fixed to the retaining portion is fixed rearward from the pillar guide portion.

4. In the vehicle seat according to claim 1, The vehicle seat is characterized in that the main body of the electrical component fixed to the reinforcing portion is fixed at a position different from the position where it is fixed to the holding portion in the left-right direction.

5. In the vehicle seat according to claim 4, The electrical component body is fixed at multiple points to either the reinforcing portion or the holding portion. The vehicle seat is characterized in that the main body of the electrical component, which is fixed to the other of the reinforcing portion and the holding portion, is fixed between each of the one of the portions which is fixed at multiple points.

6. In the vehicle seat according to claim 5, The reinforcing portion is characterized by having a plurality of fixing portions capable of fixing the main body of the electrical component, and reinforcing means provided between the plurality of fixing portions.

7. In the vehicle seat according to claim 6, The reinforcing means is characterized by having a shape that protrudes toward the seating surface and being formed so as to be able to contact at least a part of the main body of the electrical component.

8. In the vehicle seat according to claim 1, The vehicle seat is characterized in that the headrest is held to the seat back so that at least a portion of it overlaps with the electrical component body in the front-to-back direction.

9. It comprises a frame portion and a seat back having electrical components attached to the frame portion, and a headrest, The frame portion comprises a frame body, a reinforcing portion that reinforces the frame body, and a holding portion that is attached to the frame body and holds the headrest. In a method for manufacturing a vehicle seat, the aforementioned electrical component comprises an electrical component body and a wiring section connected to the electrical component body, A method for manufacturing a seat for a vehicle, characterized by comprising the step of fixing the main body of the electrical component to the reinforcing portion and the holding portion, respectively.

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