Air pump device and seat device

Abstract

To provide an air pump device which is excellent in quietness, and simple in a structure, and a seat device.SOLUTION: An air pump device 41 comprises an electric pump unit 53 having a motor 43 and a pump mechanism 44, and a case 50 for accommodating the electric pump unit 53. The air pump device 41 comprises a vibration isolation member 70 interposed between the electric pump unit 53 and the case 50. The vibration isolation member 70 is formed into a plate shape composed of a resin material having elasticity, and wound to a periphery of the electric pump unit 53 in a state of encapsulating the electric pump unit 53 at the inside. A first portion 71 of the vibration isolation member 70 is brought into a state that the first portion is sandwiched between a bottom wall 51c of a first split case 51 and the electric pump unit 53. A second portion 72 of the vibration isolation member 70 is brought into a state that the second portion is sandwiched between a bottom wall 52c of a second split case 52 and the electric pump unit 53.SELECTED DRAWING: Figure 13

Description

[Technical field]

[0001] The present invention relates to an air pump device and a seat device. [Background technology]

[0002] Conventionally, a vehicle seat device has been proposed that is capable of changing the support shape of the seat or providing a massaging effect to an occupant seated in the seat by expanding and contracting an air bag (bladder) provided inside the seat (for example, Patent Document 1).

[0003] The seat device of Patent Document 1 is configured to inflate an air bag by pumping air with an air pump device driven by a motor. The air pump device has a motor as a drive source, a pump mechanism driven by the motor, and a case that houses the motor and the pump mechanism. In addition, the air pump device has vibration-proof members interposed between the motor and the case and between the pump mechanism and the case in order to suppress the effects of vibration and noise generated by the operation of the motor and the pump mechanism. The air pump device is provided with a plurality of vibration-proof members, such as a cylindrical motor vibration-proof member extending around the axis of the motor, a cylindrical pump vibration-proof member extending around the axis of the pump mechanism, and plate-shaped vibration-proof members disposed at both ends of the axial direction of the motor and the pump mechanism. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2018-25128 A Summary of the Invention [Problem to be solved by the invention]

[0005] In the above-mentioned conventional configuration, since a plurality of vibration-isolating members, specifically a motor vibration-isolating member, a pump vibration-isolating member, and a plate-shaped vibration-isolating member, are provided inside the case, there is a problem that the structure of the air pump device becomes complicated, and this makes the assembly work of the air pump device complicated.

[0006] The present invention has been made in view of the above circumstances, and has an object to provide an air pump device and a seat device that are quiet and have a simple structure. [Means for solving the problem]

[0007] An air pump device for solving the above problem comprises an electric pump unit having a pump mechanism and a motor that drives the pump mechanism, a case that houses the electric pump unit, and an anti-vibration member interposed between the electric pump unit and the case, wherein the anti-vibration member is in the form of a plate made of an elastic resin material and is wrapped around the electric pump unit in a state where it encases the electric pump unit on the inside, and a portion of the anti-vibration member is sandwiched between the electric pump unit and one of the opposing surfaces that face each other inside the case, which is the inner surface of the case, and another portion of the anti-vibration member is sandwiched between the other of the opposing surfaces and the electric pump unit.

[0008] According to the above configuration, the vibration-proof member wrapped around the electric pump unit and stored inside the case can prevent contact between the inner surface of the case and the outer surface of the electric pump unit at various parts inside the case. This can reduce the effects of vibration and noise generated by the operation of the motor and pump mechanism, and achieve high quietness. Moreover, because this configuration can be achieved by providing a single vibration-proof member wrapped around the electric pump unit, the air pump device can have a simpler structure than a structure in which multiple vibration-proof members of various shapes are provided inside the case.

[0009] In the above air pump device, it is preferable that the case has a split structure consisting of a first split case and a second split case, and the vibration-damping member has a clamping portion extending at the joint between the first split case and the second split case and interposed between the first split case and the second split case.

[0010] According to the above configuration, even though a split case is used, the gap between the first split case and the second split case is filled by the clamping portion of the vibration-proof member, so sound leakage from the inside of the case to the outside through this gap can be suppressed, thereby achieving high quietness.

[0011] In the above air pump device, the case has a structure in which the first separate case and the second separate case are joined through engagement between a locking piece protruding from one of the first separate case and the second separate case and a locking portion provided on the outer surface of the other of the first separate case and the second separate case, and it is preferable that the clamping portion of the vibration-damping member has a through hole through which the locking piece is inserted.

[0012] According to the above-mentioned configuration, the vibration-isolating member can be attached to the case in the correct position by a simple operation of inserting the locking piece into the through hole of the clamping part of the vibration-isolating member, so that the air pump device can be easily assembled. Moreover, since the through hole of the vibration-isolating member and the locking piece of the case are engaged, the vibration-isolating member can be prevented from shifting in position relative to the case.

[0013] In the above air pump device, it is preferable that the vibration-proof member has slits extending in a predetermined pattern. According to the above-mentioned configuration, when bending the vibration-proof member for assembly, the bent shape of the vibration-proof member can be appropriately controlled by the pre-provided slits, so that the vibration-proof member can be easily assembled.

[0014] The seat device for solving the above problems is preferably one that uses an air pump device having any of the above configurations to pump air into an air bag arranged inside the seat. Effect of the Invention

[0015] According to the present invention, a vehicle seat that is excellent in quietness can be realized with a simple structure. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is a perspective view of a vehicle seat with an air bag provided inside (for seat support). [Diagram 2] FIG. 1 is a perspective view of a vehicle seat with an air bag provided inside (for massage). [Diagram 3] FIG. 2 is a schematic configuration diagram of a seat device. [Figure 4] FIG. 4 is a perspective view of an air pump device disposed in the vicinity of a side frame of a seat back. [Diagram 5] FIG. [Figure 6] FIG. [Figure 7] FIG. [Figure 8] FIG. 2 is a schematic diagram of a piston pump used in the air pump device. [Figure 9] FIG. [Figure 10] FIG. 4 is an explanatory diagram for explaining a first step. [Figure 11] FIG. [Figure 12] FIG. 2 is a cross-sectional view showing the internal structure of the air pump device at a portion where a pump mechanism is disposed. [Figure 13] FIG. 2 is an axial cross-sectional view of the air pump device. [Figure 14] FIG. 4 is a cross-sectional view showing the internal structure of the air pump device in a portion where a motor is disposed. [Figure 15] FIG. 4 is an explanatory diagram for explaining a third step. [Figure 16]FIG. 13 is an explanatory diagram for explaining a fourth step. [Figure 17] FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of a seat device having a pneumatic seat support function and a massage function and an air pump device therefor will be described with reference to the drawings. 1 and 2, a vehicle seat 1 includes a seat cushion 2 and a seat back 3 provided at the rear end of the seat cushion 2. A headrest 4 is provided at the upper end of the seat back 3.

[0018] In the seat 1 of this embodiment, the seat back 3 has both side portions 3a, 3b each bulging forward. Furthermore, the seat cushion 2 also has both side portions 2a, 2b each bulging upward. This allows the seat 1 of this embodiment to ensure a good seating position for the occupant and to maintain that seating position.

[0019] The seat 1 is also provided with a plurality of air bags 10 (11-16) that change the surface shape of the seat 1 by expanding and contracting inside the seat cushion 2 and the seat back 3. The seat 1 is also provided with a plurality of air bags 20 (21-29) that press the seat upholstery 1x from the inside by expanding and contracting inside the seat cushion 2 and the seat back 3. In this embodiment, a seat device 30 is thus formed that can change the support shape of the seat 1 and provide a massage effect (refreshing effect) to the occupant sitting in the seat 1.

[0020] Specifically, as shown in FIG. 1, in the seat 1 of this embodiment, an independent air bag 11 (11a, 11b) for seat support is provided on the inside of the seat back 3 at the shoulder portion of the backrest surface 3s. Independent air bags 12 (12a-12c), 13 for seat support are provided at positions corresponding to the lumbar portion and the lower end portion (back pelvis) on the inside of the seat back 3. Independent air bags 14 (14a, 14b) for seat support are also provided at positions corresponding to both side portions 3a, 3b of the seat back 3. In addition, independent air bags 15, 16 (16a, 16b) for seat support are also provided on the inside of the rear end portion (cushion pelvis) of the seating surface 2s and on the inside of both side portions 2a, 2b of the seat cushion 2.

[0021] 2, the inside of the seat back 3 is provided with independent massage (refreshing) air bags 21-25 aligned in the vertical direction from the shoulders to the lumbar and lower end (back pelvis) of the backrest surface 3s. Each massage air bag 20 in the seat 1 of this embodiment has a structure in which a pair of bags spaced apart in the seat width direction are connected to each other so as to expand and contract as a unit. The seat cushion 2 is also provided with independent massage air bags 27-29 aligned in the front-rear direction below the seating surface 2s.

[0022] As shown in FIG. 3, the seat device 30 of this embodiment includes an air pump device 41 that pumps air to the air bags 10, 20, and an intake and exhaust valve device 42 that is interposed between the air bags 10, 20 and the air pump device 41. The air pump device 41 of this embodiment uses an electric pump that drives a pump mechanism 44 using a motor 43 as a drive source. Furthermore, the intake and exhaust valve device 42 is connected to the air bags 10, 20 and the air pump device 41 via a flexible resin tube 45. That is, in the seat device 30 of this embodiment, an air flow path L that communicates with the air bags 10, 20 and the air pump device 41 is formed by the internal passage of the tube 45 and the intake and exhaust valve device 42. The intake and exhaust valve device 42 of this embodiment is configured such that the intake valve 46 and the exhaust valve 47 are located midway along the flow path L.

[0023] In the seat device 30 of this embodiment, the operation of each of the intake valves 46 and exhaust valve 47, as well as the air pump device 41, is controlled by a control device 48. Specifically, the internal pressure P of each of the air bags 10, 20, an operation input signal Sc for an operation switch (not shown), an ignition signal Sig, a door lock signal Sdl, and the like are input to the control device 48 of this embodiment. Based on these control signals, the control device 48 of this embodiment is configured to control the operation of each of the intake valves 46, exhaust valve 47, and the air pump device 41 to expand and contract each of the air bags 10, 20.

[0024] Next, the air pump device 41 of this embodiment will be described. As shown in Figures 4 to 7, air pump device 41 includes a case 50 that houses motor 43 and pump mechanism 44. Case 50 has a generally rectangular parallelepiped shape. Case 50 has a split structure made up of a first split case 51 and a second split case 52, both of which have a generally box-like shape with a bottom.

[0025] As shown in FIG. 7, four locking pieces 51a are protruding from the outer surface of the first separate case 51. Each locking piece 51a extends along the outer surface of the first separate case 51 in a U-shape when viewed from a direction facing the outer surface of the first separate case 51. Each locking piece 51a is shaped to protrude from the joint of the first separate case 51 toward the second separate case 52 (upper side in FIG. 7). The four locking pieces 51a are arranged on the outer surface of the first separate case 51 in a manner that they are formed at positions corresponding to the four corners of a rectangle. Meanwhile, four locked portions 52a are protruding from the outer surface of the second separate case 52. Each locked portion 52a is formed as a convex portion that engages with the locking piece 51a of the first separate case 51. The four locked portions 52a are arranged on the outer surface of the second separate case 52 in a manner that they are formed at positions corresponding to the four corners of a rectangle. In the air pump device 41 of this embodiment, the case 50 is formed by joining the first separate case 51 and the second separate case 52 through engagement between the four locking pieces 51a of the first separate case 51 and the four locked portions 52a of the second separate case 52.

[0026] As shown in FIG. 4, the seat device 30 of this embodiment is configured such that the air pump device 41 is disposed inside the seat 1, in the vicinity of a side frame 3f that constitutes the framework of the seat back 3.

[0027] As shown in Fig. 7, in air pump device 41 of this embodiment, motor 43 and pump mechanism 44 are integrated into electric pump unit 53 with pump mechanism 44 disposed in the axial direction of motor 43. Motor 43 of this embodiment has a substantially cylindrical outer shape extending in the axial direction (indicated by N in Fig. 7), and pump mechanism 44 of this embodiment has a substantially rectangular prism outer shape. Electric pump unit 53 of this embodiment is configured to be housed inside case 50 with the axis of motor 43 aligned along the longitudinal direction.

[0028] The pump mechanism 44 has an air intake port 54 at an axial end 44a opposite the motor 43 in the axial direction of the motor 43. In the air pump device 41 of the present embodiment, the intake port 54 of the pump mechanism 44 is disposed inside the case 50.

[0029] The pump mechanism 44 has an air discharge port 55 at the axial end 44a on the side where the suction port 54 is provided. Specifically, in the pump mechanism 44 of this embodiment, the discharge port 55 is configured to include a tube 56 extending from the axial end 44a and a joint 57 connected to the tip of the tube 56. In addition, the case 50 of this embodiment has a through hole 58 in the side walls 51b, 52b facing the axial end 44a of the pump mechanism 44 where the discharge port 55 is provided. Furthermore, a rubber bush 59 is fitted into the through hole 58. In the air pump device 41 of this embodiment, the tip side of the tube 56 constituting the discharge port 55 is drawn out to the outside of the case 50 through an insertion hole 59a provided in the rubber bush 59.

[0030] 4, the air pump device 41 of this embodiment is arranged such that the long shape of the electric pump unit 53 extending in the axial direction of the motor 43 is aligned with the side frame 3f of the seat back 3. As a result, the tube 56 constituting the discharge port 55 is drawn out to the upper side of the case 50.

[0031] As shown in Fig. 8, the pump mechanism 44 has a configuration as an axial type piston pump. Specifically, the pump mechanism 44 includes a drive shaft 61 that rotates by the driving force of the motor 43, and a cylinder block 64 having a plurality of cylinders 63 arranged at positions eccentric to the drive shaft 61. The pump mechanism 44 also includes a plurality of pistons (plungers) 65 arranged in each cylinder 63 with their base ends 65a protruding out of the cylinder block 64. The pump mechanism 44 also includes a swash plate 66 that rotates integrally with the drive shaft 61 with the base ends 65a of the pistons 65 in contact with each other.

[0032] That is, in the pump mechanism 44, as the swash plate 66 rotates, the contact position of each piston 65 with respect to the swash plate 66 is displaced in the axial direction of the drive shaft 61. As a result, each piston 65 reciprocates within each cylinder 63.

[0033] Furthermore, at the end of the cylinder block 64 opposite to the swash plate 66 (the upper end in FIG. 8), there is provided a flow path M that communicates each of the cylinders 63 with the suction port 54 and the discharge port 55. Furthermore, in this flow path M, a branch line M1 that branches off from the main line M0 and extends to the suction port 54, and a branch line M2 that extends to the discharge port 55 are provided with check valves 68 in the middle of each of the branch lines M1 and M2, respectively, that prevent backflow of air. Thus, the pump mechanism 44 of this embodiment is configured to pump and deliver air sucked from the suction port 54 through the discharge port 55 based on the volumetric change of each of the cylinders 63 accompanying the reciprocating motion of each of the pistons 65.

[0034] The pump mechanism 44 has these components (61-68) housed in a housing 69 having a substantially rectangular prism shape (see FIG. 7). Specifically, within the housing 69, the cylinder block 64 is arranged such that the cylinders 63 extend along the axial direction of the motor 43 (the vertical direction in FIG. 8). This allows the pump mechanism 44 to have a reduced radial dimension.

[0035] 5 to 7, air pump device 41 of the present embodiment has a vibration-proof member 70. Vibration-proof member 70 is attached in a manner such that it is interposed between the inner surface of case 50 and the outer surface of electric pump unit 53, and also between first separate case 51 and second separate case 52. In air pump device 41 of the present embodiment, vibration and noise generated in association with the operation of motor 43 and pump mechanism 44 are absorbed by this vibration-proof member 70.

[0036] The vibration-isolating member 70 will now be described in detail. First, the shape of the vibration-isolating member 70 before it is attached will be described. 7 and 9, the vibration-proof member 70 has a long flat plate shape in a free state before attachment. The vibration-proof member 70 is made of an elastic resin material (in this embodiment, low-flammability urethane foam [UEI]). The vibration-proof member 70 is attached in a manner of being wrapped around the electric pump unit 53.

[0037] At both ends in the longitudinal direction of the vibration-proof member 70, there are provided cutout portions 70a, 70b that are cut out with a U-shaped cross section. These cutout portions 70a, 70b are formed at positions where the tube 56 and rubber bushing 59 are disposed when the air pump device 41 is assembled. By providing such cutout portions 70a, 70b in the vibration-proof member 70, unnecessary interference between the vibration-proof member 70 and the tube 56 and rubber bushing 59 is suppressed.

[0038] The vibration-proof member 70 has a narrow width portion 70c in the middle in the longitudinal direction, where the width (the length in the vertical direction in FIG. 9) is partially narrowed. In this embodiment, when assembling the air pump device 41, the vibration-proof member 70 is folded back at the narrow width portion 70c. In this embodiment, the vibration-proof member 70 is provided with the narrow width portion 70c in order to properly fold back the vibration-proof member 70.

[0039] The vibration-proof member 70 has a plurality of slits 70d. These slits 70d penetrate the vibration-proof member 70 in the thickness direction and extend in a predetermined pattern. Each slit 70d is provided in a portion where the vibration-proof member 70 will be folded when assembling the air pump device 41. By providing such slits 70d in the vibration-proof member 70, the vibration-proof member 70 can be folded smoothly.

[0040] The vibration-proof member 70 has a first portion 71 that constitutes one side in the longitudinal direction (the left side in FIG. 9), and a second portion 72 that constitutes the other side (the right side in FIG. 9). The first portion 71 has a first peripheral portion 73 that constitutes its peripheral portion, and a first central portion 74 that constitutes its central portion.

[0041] Four first through holes 73a are provided in the first peripheral portion 73. Each of the first through holes 73a is a linear cut extending in the longitudinal direction. In this embodiment, the four first through holes 73a provided in the first portion 71 of the vibration-proof member 70 and the four locking pieces 51a of the first separate case 51 (see FIG. 7) are arranged in such a manner that they are formed at positions corresponding to the four corners of the same rectangle. When assembling the air pump device 41, the four locking pieces 51a of the first separate case 51 are configured to be inserted into the four first through holes 73a of the first portion 71 of the vibration-proof member 70, respectively.

[0042] The first central portion 74 has a first pump portion 74a which constitutes the cutout portion 70a side, and a first motor portion 74b which constitutes the second portion 72 side. The first pump portion 74a has a rectangular plate shape, and the end portion on the cutout portion 70a side (left side in Figure 9) is not separated from the first surrounding portion 73, and the other portions are separated from the first surrounding portion 73.

[0043] The first motor part 74b is plate-shaped, and its end part on the second portion 72 side (right side in FIG. 9) is not separated from the first surrounding part 73, and the other parts are separated from the first surrounding part 73. The first motor part 74b has a rectangular part on the tip side (left side in FIG. 9) and a tapered part on the base end side (right side in FIG. 9) that becomes wider as it approaches the base end.

[0044] The second part 72 of the vibration-proof member 70 has a second central part 75 constituting a central part in the width direction, and two sets of second legs 76 provided at positions sandwiching the second central part 75 in the width direction. Each second leg 76 is provided with a second through hole 76a. The second through hole 76a is a linear cut extending in the longitudinal direction. The four second legs 76 provided in the second part 72 are arranged in such a manner that the second through holes 76a of each second leg 76 are formed at positions corresponding to the four corners of a rectangle. In this embodiment, when assembling the air pump device 41, the four locking pieces 51a of the first separate case 51 are structured to be inserted into the four second through holes 76a of the second part 72 of the vibration-proof member 70, respectively.

[0045] Next, a procedure for assembling the air pump device 41 of this embodiment will be described. When assembling the air pump device 41, the first step is carried out first. (1st step) 7, 9 and 10, in this first step, the vibration-proof member 70 is attached to the first separate case 51 by inserting the four locking pieces 51a of the first separate case 51 into the four first through holes 73a of the first portion 71 of the vibration-proof member 70. Thus, in this embodiment, the vibration-proof member 70 can be attached to the first separate case 51 while being positioned by the simple task of inserting the four locking pieces 51a into the four first through holes 73a respectively.

[0046] (2nd process) After the first step, the second step is carried out. As shown in Figures 7, 9 and 11, in the second step, approximately half of the electric pump unit 53 is fitted into the first split case 51 in such a manner that the first central portion 74 of the first part 71 of the vibration-damping member 70 is pushed into the first split case 51.

[0047] Specifically, the pump mechanism 44 of the electric pump unit 53 is attached in such a manner that the portion of the first central portion 74 of the vibration-proof member 70 on the side of the notch 70a (first pump portion 74a) is pressed into the inside of the first separate case 51.

[0048] As shown in Figs. 12 and 13, when the pump mechanism 44 is attached, a part of the first pump section 74a of the vibration-proof member 70 is sandwiched between the axial end 44a of the pump mechanism 44 and a portion (side wall 51b) of the first separate case 51 that faces the axial end 44a. At this time, the remaining part of the first pump section 74a of the vibration-proof member 70 is sandwiched between the bottom wall 51c of the first separate case 51 and the outer surface of the pump mechanism 44. This reduces contact between the inner surfaces of the side walls 51b and the bottom wall 51c of the first separate case 51 and the outer surface of the pump mechanism 44. Furthermore, the pump mechanism 44 is sandwiched between the inner surfaces of the first peripheral portion 73 of the first portion 71 of the vibration-proof member 70 with a gap formed between the pump mechanism 44 and both side walls 51d in the width direction (left and right direction in Fig. 12) of the first separate case 51. This reduces contact between the outer surface of the pump mechanism 44 and the inner surfaces of both side walls 51d of the first separate case 51.

[0049] On the other hand, as shown in Figures 7, 9 and 11, the motor 43 of the electric pump unit 53 is attached in a manner such that the portion of the first central portion 74 of the vibration-proof member 70 on the side of the second portion 72 (first motor portion 74b) is pressed into the inside of the first separate case 51.

[0050] As shown in FIG. 13 and FIG. 14, a part of the first motor section 74b of the vibration-proof member 70 is sandwiched between the axial end section 43a of the motor 43 on the opposite side to the pump mechanism 44 in the axial direction and a section (side wall 51e) of the first separate case 51 facing the axial end section 43a. At this time, the remaining part of the first motor section 74b of the vibration-proof member 70 is sandwiched between the bottom wall 51c of the first separate case 51 and the outer surface of the motor 43. This prevents the inner surfaces of the side wall 51e and bottom wall 51c of the first separate case 51 from contacting the outer surface of the motor 43. In this embodiment, the first central section 74 of the first part 71 corresponds to a part of the vibration-proof member sandwiched between the inner surface of the case and the electric pump unit. In this embodiment, the inner surface of the bottom wall 51c of the first separate case 51 corresponds to one of the opposing surfaces facing each other inside the case.

[0051] Furthermore, as shown in FIG. 14, when the motor 43 is attached, the inner edge portion of the first peripheral portion 73 of the vibration-proof member 70 is pushed out toward the inside of the first separate case 51 by the outer peripheral surface of the motor 43. At this time, the inner edge portion of the first peripheral portion 73 of the vibration-proof member 70 is sandwiched between the outer peripheral surface of the motor 43 and the inner surfaces of both side walls 51d of the first separate case 51. As a result, the inner edge portion of the first peripheral portion 73 of the vibration-proof member 70 is pressed against the outer peripheral surface of the motor 43 on both sides in the width direction of the motor 43. Therefore, contact between the outer peripheral surface of the motor 43 and the inner surfaces of both side walls 51d of the first separate case 51 is suppressed, and the motor 43 is firmly supported by the inner edge portion of the first peripheral portion 73 of the vibration-proof member 70 inside the first separate case 51.

[0052] (3rd step) After the second step, the third step is carried out. As shown in Figs. 7, 9 and 15, in the third step, the vibration-proof member 70 is folded back at a portion (narrow portion 70c) between the first portion 71 and the second portion 72. The second central portion 75 of the second portion 72 of the vibration-proof member 70 is folded back so as to have a hat-shaped cross section in a manner extending in the axial direction along the outer surface of the electric pump unit 53. Furthermore, in this state, the four second legs 76 of the second portion 72 are overlapped on the first peripheral portion 73 of the first portion 71, and the second through holes 76a of the second legs 76 are inserted into the four locking pieces 51a of the first separate case 51, respectively. In this manner, in this embodiment, the second portion 72 of the vibration-proof member 70 can be attached to a predetermined position by simple operations such as folding the vibration-proof member 70 along the outer surface of the electric pump unit 53 and inserting the four locking pieces 51a into the four second through holes 76a.

[0053] (4th step) After the third step, the fourth step is carried out. As shown in Figures 7, 15 and 16, in the fourth step, the second separate case 52 is assembled to the first separate case 51 in such a manner that the four locking pieces 51a of the first separate case 51 are individually engaged with the four locked portions 52a of the second separate case 52.

[0054] As shown in Figs. 12 and 13, when the second separate case 52 is assembled in this manner, the second central portion 75 of the second part 72 of the vibration-proof member 70 is sandwiched between the inner surface of the second separate case 52 and the outer surface of the electric pump unit 53. More specifically, the portion of the second central portion 75 on the cutout portion 70b side (left side in Fig. 13) is sandwiched between the axial end 44a of the pump mechanism 44 and the portion (side wall 52b) of the second separate case 52 facing the axial end 44a. Also, the central portion of the second central portion 75 in the longitudinal direction (left-right direction in Fig. 13) is sandwiched between the bottom wall 52c of the second separate case 52 and the outer surface of the electric pump unit 53. Furthermore, the portion of the second central portion 75 on the folded-back portion (narrow portion 70c) side is sandwiched between the axial end 43a of the motor 43 and the portion (side wall 52e) of the second separate case 52 facing the axial end 43a of the second separate case 52. This prevents contact between the outer surface of the electric pump unit 53 and the side walls 52b, 52e and bottom wall 52c of the second separate case 52. In this embodiment, the second central portion 75 of the second part 72 corresponds to the other part of the vibration-proof member sandwiched between the inner surface of the case and the electric pump unit. In this embodiment, the inner surface of the bottom wall 52c of the second separate case 52 corresponds to the other of the opposing surfaces facing each other inside the case. Furthermore, the pump mechanism 44 is sandwiched between the inner surfaces of a pair of second legs 76 of the second part 72, which are provided at a position sandwiching the pump mechanism 44, with a gap formed between both side walls 52d in the width direction (left and right direction in FIG. 12) of the second separate case 52. This prevents contact between the outer surface of the pump mechanism 44 and the inner surface of the second separate case 52.

[0055] On the other hand, as shown in FIG. 14, the inner edge portions of the pair of second legs 76 of the second part 72 provided at a position sandwiching the motor 43 are pushed outward toward the inside of the second separate case 52 by the outer circumferential surface of the motor 43. At this time, the inner edge portions of the pair of second legs 76 are sandwiched between the outer circumferential surface of the motor 43 and the inner surfaces of both side walls 52d of the second separate case 52. As a result, the inner edge portions of the second legs 76 of the vibration-proof member 70 are pressed against the outer circumferential surface of the motor 43 on both sides in the width direction of the motor 43. Therefore, contact between the outer circumferential surface of the motor 43 and the inner surfaces of both side walls 52d of the second separate case 52 is suppressed, and the motor 43 is firmly supported by the inner edge portions of the second legs 76 of the vibration-proof member 70 inside the second separate case 52.

[0056] In this manner, in air pump device 41 of the present embodiment, electric pump unit 53 is housed inside case 50 made up of first separate case 51 and second separate case 52. As shown in Figures 12 to 14, in this embodiment, inside case 50, vibration-proof member 70 is wrapped around electric pump unit 53 in a state where electric pump unit 53 is wrapped on the inside.

[0057] In the air pump device 41 of this embodiment, the first peripheral portion 73 of the first portion 71 and the four second leg portions 76 of the second portion 72 of the vibration-proof member 70 are sandwiched between the first separate case 51 and the second separate case 52. The first peripheral portion 73 of the first portion 71 and the four second leg portions 76 of the second portion 72 form a sandwiching portion 77 interposed between the first separate case 51 and the second separate case 52 in a manner that extends at the joint between the first separate case 51 and the second separate case 52. The sandwiching portion 77 closes the gap between the first separate case 51 and the second separate case 52 in a state that it is partially compressed between the first separate case 51 and the second separate case 52. By providing such a sandwiching portion 77, sound leakage from the joint between the first separate case 51 and the second separate case 52 is suppressed, and an effect of suppressing noise is obtained.

[0058] Here, when fitting the second separate case 52 into the first separate case 51 in the fourth step, it is necessary to compress the clamping portion 77 of the vibration-proof member 70 by a predetermined amount between the first separate case 51 and the second separate case 52. Therefore, depending on the shape (e.g., thickness) of the clamping portion 77, a large force may be required when fitting the second separate case 52 into the first separate case 51.

[0059] In this regard, in the air pump device 41 of this embodiment, the portion of the sandwiching portion 77 of the vibration-proof member 70 between the two adjacent second legs 76 in the longitudinal direction is composed only of the first portion 71. As a result, the thickness of the portion of the sandwiching portion 77 of the vibration-proof member 70 between the two adjacent second legs 76 in the longitudinal direction is thinner than the thickness of the other portions. Therefore, in the air pump device 41 of this embodiment, the sandwiching portion 77 of the vibration-proof member 70 can be compressed by a required amount with a smaller force than in the case where the second portion 72 is also disposed in the portion between the two second legs 76. Therefore, the work of attaching the second separate case 52 to the first separate case 51, and therefore the work of assembling the air pump device 41 can be easily performed.

[0060] Next, a fixing structure of the air pump device 41 in the seat device 30 will be described. As shown in FIGS. 5, 6 and 17, the seat device 30 of this embodiment includes a vibration isolation device 80 interposed between the air pump device 41 and the seat 1 (the framework of the seat back 3).

[0061] More specifically, the vibration isolation device 80 of this embodiment includes a pair of mounting brackets 81 that are engaged with the case 50 of the air pump device 41, and an intermediate bracket 82 that is engaged with a fixed bracket (not shown) provided on the frame side of the seat back 3. The vibration isolation device 80 also includes a pair of rubber bushings 83 that are interposed between the mounting brackets 81 and the intermediate bracket 82.

[0062] The mounting bracket 81 of this embodiment includes a pump engaging portion 84 having a substantially flat plate shape, and a bush engaging portion 85 having a substantially C-ring shape provided at one end of the pump engaging portion 84. The rubber bush 83 of this embodiment has a substantially flat, cylindrical outer shape. An engaging groove 83a is formed on an outer circumferential surface 83s of the rubber bush 83, extending over the entire circumference. The bush engaging portion 85 of the mounting bracket 81 is provided with an engaging protrusion 85a having a substantially C-ring shape protruding radially inward from its inner circumference.

[0063] That is, in the mounting bracket 81 of this embodiment, the bushing engagement portion 85 engages with the outer peripheral surface 83s of the rubber bushing 83 with the engagement protrusion 85a disposed in the engagement groove 83a on the rubber bushing 83 side. The air pump device 41 of this embodiment also has bracket locking portions 86 at both longitudinal ends of the case 50. Specifically, each of these bracket locking portions 86 has a substantially L-shaped cross section and a pair of locking pieces 86a facing each other in the lateral direction of the case 50. Each mounting bracket 81 of this embodiment is configured to be locked to the longitudinal end of the case 50 with the pump engagement portion 84 sandwiched between the two locking pieces 86a.

[0064] Meanwhile, the intermediate bracket 82 of this embodiment has a long, generally plate-like outer shape with through holes 82a at both ends in the longitudinal direction. Also, the rubber bushings 83 of this embodiment are provided with a through hole 87 that passes through the axial center portion of the generally cylindrical shape. Furthermore, in the vibration-proof device 80 of this embodiment, crimping pins 88 are inserted into the through holes 82a of the intermediate bracket 82 and the through holes 87 of the rubber bushings 83. And, in the vibration-proof device 80 of this embodiment, a pair of rubber bushings 83 are interposed between the intermediate bracket 82 and each mounting bracket 81 by crimping both ends of each crimping pin 88.

[0065] That is, the vibration-proof device 80 of this embodiment allows relative displacement between the intermediate bracket 82 and each mounting bracket 81 in the axial and radial directions of each crimp pin 88 by elastically deforming each of these rubber bushings 83. Furthermore, the amount of relative displacement occurring between the intermediate bracket 82 and each mounting bracket 81 is damped based on the elastic force (elastic restoring force) of each of these rubber bushings 83. Thus, the vibration-proof device 80 of this embodiment is configured to absorb vibrations occurring in the air pump device 41.

[0066] As described above, according to this embodiment, the following advantageous effects can be obtained. (1) The air pump device 41 has a vibration-proof member 70 interposed between the outer surface of the electric pump unit 53 and the inner surface of the case 50. The vibration-proof member 70 is formed in a plate shape from an elastic resin material, and is attached in a state in which it is wrapped around the electric pump unit 53 with the electric pump unit 53 wrapped inside. A first portion 71 of the vibration-proof member 70 is sandwiched between the bottom wall 51c of the first separate case 51 and the electric pump unit 53. A second portion 72 of the vibration-proof member 70 is sandwiched between the bottom wall 52c of the second separate case 52 and the electric pump unit 53.

[0067] According to the air pump device 41 of this embodiment, the vibration-proof member 70, which is wrapped around the electric pump unit 53 and stored inside the case 50, can suppress contact between the inner surface of the case 50 and the outer surface of the electric pump unit 53 at various parts inside the case 50. The vibration-proof member 70 can absorb the displacement of the electric pump unit 53 inside the case 50. Furthermore, by providing such a vibration-proof member 70, it is possible to obtain an effect of absorbing the sound generated with the operation of the electric pump unit 53 (more specifically, the motor 43 and the pump mechanism 44) and an effect of blocking the sound and suppressing sound leakage to the outside of the case 50. Therefore, according to the air pump device 41 of this embodiment, the influence of vibrations and noise generated with the operation of the motor 43 and the pump mechanism 44 can be suppressed, and high quietness can be obtained.

[0068] Moreover, this configuration can be achieved by providing one vibration-proof member 70 that wraps around electric pump unit 53. Therefore, air pump device 41 can have a simpler structure than a structure in which a plurality of vibration-proof members of various shapes are provided inside case 50.

[0069] (2) The case 50 has a split structure made up of a first separate case 51 and a second separate case 52. The vibration-proof member 70 extends at the joint between the first separate case 51 and the second separate case 52 and includes a clamping portion 77 interposed between the first separate case 51 and the second separate case 52.

[0070] According to this air pump device 41, even though a split case 50 is employed, the gap between the first split case 51 and the second split case 52 can be filled by the clamping portion 77 of the vibration-proof member 70. This makes it possible to prevent sound from leaking from the inside of the case 50 to the outside through the gap between the first split case 51 and the second split case 52, thereby achieving high quietness.

[0071] (3) Four locking pieces 51a protrude from the first separate case 51. Four locked portions 52a are formed on the outer surface of the second separate case 52. The case 50 is structured such that the first separate case 51 and the second separate case 52 are joined together through the engagement between the four locking pieces 51a and the four locked portions 52a. The clamping portion 77 of the vibration-proof member 70 has through holes 73a, 76a through which the locking pieces 51a of the first separate case 51 are inserted. More specifically, four first through holes 73a are formed in the first periphery 73 of the first portion 71 constituting the clamping portion 77, and second through holes 76a are formed in the four second foot portions 76 of the second portion 72 constituting the clamping portion 77.

[0072] With this air pump device 41, the vibration-proof member 70 can be attached to the first separate case 51 while being positioned by the simple operation of inserting the four locking pieces 51a of the first separate case 51 into the four first through holes 73a of the vibration-proof member 70. Moreover, the second portion 72 of the vibration-proof member 70 can be attached to a predetermined position by the simple operation of bending the vibration-proof member 70 along the outer surface of the electric pump unit 53 and inserting the four locking pieces 51a into the four second through holes 76a.

[0073] In this manner, the vibration-proof member 70 can be attached to the case 50 in the correct position through the simple operation of inserting the locking pieces 51a of the first separate case 51 into the through holes 73a, 76a of the vibration-proof member 70. This facilitates assembly of the air pump device 41. Moreover, because the through holes 73a, 76a of the vibration-proof member 70 and the locking pieces 51a of the case 50 are engaged with each other, displacement of the vibration-proof member 70 relative to the case 50 can be suppressed.

[0074] (4) The vibration-proof member 70 has slits 70d formed therein that extend in a predetermined pattern. As a result, when the vibration-proof member 70 is bent during assembly, the slits 70d allow the bending shape of the vibration-proof member 70 to be appropriately controlled. This makes it easy to assemble the vibration-proof member 70.

[0075] The above embodiment can be modified as follows: The above embodiment and the following modifications can be combined with each other to the extent that no technical contradiction occurs. The structure for joining the first separate case 51 and the second separate case 52 can be any structure, such as a structure in which a protruding piece protruding from the outer surface of one of the first separate case 51 and the second separate case 52 is welded to the outer surface of the other.

[0076] The shapes of the first separate case 51 and the second separate case 52 may be changed as desired as long as they are capable of housing the electric pump unit 53 surrounded by the vibration-proof member 70.

[0077] Some of the four through holes 73a, 76a through which the locking pieces 51a of the first separate case 51 are inserted in the clamping portion 77 of the vibration-proof member 70 may be omitted, provided that the clamping portion 77 of the vibration-proof member 70 has a shape that does not interfere with the joining of the first separate case 51 and the second separate case 52. It is also possible to omit all of the four through holes 73a, 76a in the clamping portion 77 of the vibration-proof member 70.

[0078] If the vibration-proof member 70 is wrapped around the electric pump unit 53 inside the case 50, the clamping portion 77, which is the part of the vibration-proof member 70 interposed between the first separate case 51 and the second separate case 52, may be omitted.

[0079] In the above embodiment, the pump mechanism 44 is a piston pump having the cylinder 63 extending in the axial direction of the motor 43. However, the type of the pump mechanism 44 may be changed arbitrarily.

[0080] The slit 70d does not necessarily have to penetrate the vibration-proof member 70 in the thickness direction, but may extend partway through the vibration-proof member 70 in the thickness direction. The formation pattern of the slits 70d in the vibration-proof member 70 can be changed as desired.

[0081] In the above embodiment, the vibration isolator 80 has its mounting bracket 81 engaged with the outer circumferential surface 83s of the rubber bushing 83. Furthermore, in the vibration isolator 80, the intermediate bracket 82 locks the crimp pin 88 and the rubber bushing 83 in a state in which the rubber bushing 83 is elastically deformable in the axial and radial directions of the crimp pin 88. However, the vibration isolator 80 may have a configuration in which the intermediate bracket 82 engages with the outer circumferential surface 83s of the rubber bushing 83, and the mounting bracket 81 locks the crimp pin 88 and the rubber bushing 83 in a state in which the rubber bushing 83 is elastically deformable in the axial and radial directions of the crimp pin 88.

[0082] The number of rubber bushes 83 may be one or three or more. When a plurality of rubber bushes 83 are provided, it is preferable that these rubber bushes 83 are disposed at positions spaced apart from each other in the longitudinal direction of the air pump device 41.

[0083] In the above embodiment, the air pump device 41 is disposed inside the seat back 3 along the side frame 3f thereof. However, the arrangement may be changed as desired, for example, to be disposed inside the seat cushion 2. [Explanation of symbols]

[0084] 1...Sheet 2. Seat cushion 3…Seat back 3f…Side frame 4. Headrest 10(11~16), 20(21~29)…Air bag 30...Seat device 41...Air pump device 42...Intake and exhaust valve device 43…Motor 44…Pump mechanism 50…case 51…First split case 51a...locking piece 51c…Bottom wall 52…Second separate case 52a...Locked part 52c…Bottom wall 53...Electric pump unit 70...Vibration-proof member 70c…Narrow part 70d…Cut 71…Part 1 72…Second part 73…First peripheral part 73a...1st through hole 74...1st central part 74a…First pump section 74b…First motor section 75…Second central part 76...Second leg 76a…Second through hole 77...Holding part 80…Vibration isolation device

Claims

1. an electric pump unit having a pump mechanism and a motor for driving the pump mechanism; a case that houses the electric pump unit; a vibration isolating member interposed between the electric pump unit and the case, the vibration-proof member is a plate-like member made of an elastic resin material, and is wrapped around the electric pump unit in a state where the electric pump unit is wrapped inside the vibration-proof member, a portion of the vibration-proof member is sandwiched between one of opposing surfaces that are an inner surface of the case and that face each other inside the case and the electric pump unit, the other portion of the vibration-proof member is sandwiched between the other of the opposing surfaces and the electric pump unit, the case has a split structure including a first split case and a second split case, the vibration-proof member includes a clamping portion extending at a joint between the first separate case and the second separate case and interposed between the first separate case and the second separate case, the case has a structure in which the first separate case and the second separate case are joined together through engagement between a locking piece protruding from one of the first separate case and the second separate case and a locked portion provided on an outer surface of the other of the first separate case and the second separate case, An air pump device in which the clamping portion of the vibration-proof member has a through hole through which the locking piece is inserted.

2. The vibration isolation member has cuts extending in a predetermined pattern.

2. The air pump device according to claim 1.

3. 3. A seat assembly in which air is pumped into an air bag disposed inside a seat by using the air pump device according to claim 1.

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