Sheet

Abstract

To provide a seat that has a large amount of deflection in a low-load condition and that comprises a pad hardly associated with a bottom touching feeling.SOLUTION: A vehicle seat S includes a seat frame (cushion frame F1), a pad (cushion pad 30) that covers the seat frame, and a skin material 40 that covers the pad. The pad has a first pad layer (urethane layer 31) that is made of a urethane foam, and a second pad layer (latex layer 32) that is arranged between the first pad layer and the skin material 40. The second pad layer is made of profile urethane, a net-like resin structure or a latex foam.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a seat provided with a pad for supporting a seated person.

Background Art

[0002] Conventionally, a seat including a seat frame and a pad covering the seat frame has been known (see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, it is desired that the pad has a large amount of deflection under a low load and is difficult to feel a bottoming feeling in order to improve the sitting comfort.

[0005] Therefore, an object of the present invention is to provide a seat provided with a pad having a large amount of deflection under a low load and being difficult to feel a bottoming feeling.

Means for Solving the Problems

[0006] To solve the above problems, a seat according to the present invention includes a seat frame, a pad covering the seat frame, and a skin material covering the pad. The pad has a first pad layer made of urethane foam and a second pad layer disposed between the first pad layer and the skin material. The second pad layer is made of profile urethane, a reticulated resin structure, or latex foam.

[0007] According to this configuration, since the second pad layer disposed between the skin material and the first pad layer made of urethane foam is made of profile urethane, a reticulated resin structure, or latex foam, the pad can be structured to have a large amount of deflection under a low load and be less likely to feel a sense of having a bottom.

[0008] Further, the pad may have a third pad layer disposed between the second pad layer and the skin material, the second pad layer may be made of latex foam, and the third pad layer may be made of profile urethane or a reticulated resin structure.

[0009] Further, the pad may have a fourth pad layer disposed between the third pad layer and the skin material, the third pad layer may be made of a reticulated resin structure, and the fourth pad layer may be made of profile urethane.

[0010] Further, the pad may have a high-hardness slab layer disposed between the second pad layer and the third pad layer, which is harder than the urethane foam.

[0011] Further, the pad may have a soft slab layer disposed between the fourth pad layer and the skin material, which is softer than the urethane foam.

[0012] Further, the pad may have a low-rebound slab layer disposed between the fourth pad layer and the soft slab layer, which has a lower resilience than the urethane foam.

[0013] Further, the sheet may be an S spring bridged over the sheet frame, and may include an S spring that supports the first pad layer.

[0014] Further, the pad may have a third pad layer disposed between the second pad layer and the skin material, the second pad layer may be made of a reticulated resin structure, and the third pad layer may be made of profile urethane.

[0015] Further, the pad may have left and right side portions that sandwich the second pad layer from the left - right direction, and the side portions may be harder than the second pad layer.

[0016] According to this configuration, since the second pad layer is sandwiched from the left - right direction by the left and right side portions that are harder than the second pad layer, it is possible to favorably suppress the second pad layer from shifting left and right.

[0017] Also, the left and right side portions and the first pad layer may be integrally formed.

[0018] According to this configuration, compared with the case where the side portions and the first pad layer are separate members, the structure of the pad can be simplified.

Advantages of the Invention

[0019] According to the present invention, it is possible to provide a seat provided with a pad that has a large amount of deflection under a low load and is less likely to feel a sense of having a bottom.

[0020] Also, by making the left and right side portions that sandwich the first pad layer and the second pad layer from the left - right direction harder than the second pad layer, it is possible to favorably suppress each pad layer from shifting left and right by the side portions.

[0021] Also, by integrally forming the left and right side portions and the first pad layer, the structure of the pad can be simplified.

Brief Description of the Drawings

[0022]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Mode for Carrying Out the Invention

[0023] [First Embodiment] Hereinafter, the first embodiment of the present invention will be described with reference to the accompanying drawings. In this specification, front and rear, left and right, and up and down are based on the front and rear, left and right, and up and down as seen by a person sitting on the seat. As shown in FIG. 1, the seat of this embodiment is configured as a vehicle seat S mounted on an automobile, and includes a seat cushion S1, a seat back S2, and a headrest S3.

[0024] The seat cushion S1 is formed by covering a cushion frame F1 (see FIG. 2), which is an example of a seat frame, with a cushion pad 30, which is an example of a pad, and a skin material 40. The seat back S2 is formed by covering a back frame F2 (see FIG. 2) with a pad and a skin material. Although not shown, the headrest S3 is also formed by covering a headrest frame with a pad and a skin material.

[0025] As shown in FIG. 2, the cushion frame F1 is installed on the floor of the automobile via a slide rail SL, whereby the vehicle seat S can be adjusted in the front-rear position. Further, the lower part of the back frame F2 is rotatably connected to the rear part of the cushion frame F1 via a reclining mechanism RL.

[0026] The back frame F2 is mainly composed of an upper frame 21, left and right seat back side frames 22, and a lower frame 23, and is formed in a frame shape in which the upper frame 21, the left and right seat back side frames 22, and the lower frame 23 are integrally joined by welding or the like.

[0027] The upper frame 21 is composed of a pipe material bent in a substantially U shape. On the front side of the horizontal pipe portion 21A extending in the left - right direction, a pair of left - and - right support brackets 21B for attaching the headrest S3 are fixed by welding. Further, the left - and - right vertical pipe portions 21C of the upper frame 21 extending in the up - down direction are integrally formed with the left - and - right plate - shaped side - frame main body portions 22A coupled to their lower portions, respectively, to form the left - and - right seat - back side frames 22.

[0028] The cushion frame F1 is mainly composed of left - and - right cushion side frames 11, a pan frame 12, and a rear connecting pipe 13. The left - and - right cushion side frames 11, the pan frame 12, and the rear connecting pipe 13 are integrally joined by welding or the like to form a frame shape. Inside this frame - shaped cushion frame F1, a deformable S - spring 14 that supports the occupant together with the cushion pad 30 (see FIG. 1) is spanned in the front - rear direction between the pan frame 12 and the rear connecting pipe 13. In the present embodiment, four S - springs 14 are provided side - by - side in the left - right direction.

[0029] As shown in FIG. 3, the cushion pad 30 has a urethane layer 31 as an example of the first pad layer, a latex layer 32 as an example of the second pad layer, a high - hardness slab layer 33, and a soft slab layer 34. The urethane layer 31 is made of urethane foam obtained by foaming polyurethane and is in contact with the cushion frame F1.

[0030] As shown in FIGS. 3 and 4, the urethane layer 31 has a base portion 31A with a predetermined thickness supported by the S - spring 14, and front - rear - left - and - right side portions 31B - 31E integrally formed on the front, rear, left, and right of the base portion 31A.

[0031] The front - rear - left - and - right side portions 31B - 31E project upward from the base portion 31A. The front and rear side portions 31B, 31C sandwich the base portion 31A, the latex layer 32, and the high - hardness slab layer 33 in the front - rear direction. The upper surfaces of the front and rear side portions 31B, 31C are substantially flush with the upper surface of the high - hardness slab layer 33.

[0032] The left and right side portions 31D and 31E sandwich the base portion 31A, the latex layer 32, the high-hardness slab layer 33, and the soft slab layer 34 from the left and right directions. The left and right side portions 31D and 31E protrude above the soft slab layer 34.

[0033] The latex layer 32 is made of a latex foam obtained by foaming natural rubber. The latex layer 32 has a plurality of holes 32A penetrating in the vertical direction. The latex layer 32 is laminated on the base portion 31A. The latex layer 32 is more elastic than the urethane layer 31. Note that the holes of the latex layer do not have to be through holes, and for example, a plurality of holes with bottoms may be formed on the upper and lower surfaces of the latex layer.

[0034] The high-hardness slab layer 33 is made of a urethane foam harder than the urethane foam constituting the urethane layer 31. Specifically, the density of the urethane foam constituting the high-hardness slab layer 33 is greater than the density of the urethane foam constituting the urethane layer 31. The high-hardness slab layer 33 is laminated on the latex layer 32.

[0035] The soft slab layer 34 is made of a urethane foam softer than the urethane foam constituting the urethane layer 31. Specifically, the density of the urethane foam constituting the soft slab layer 34 is smaller than the density of the urethane foam constituting the urethane layer 31. The soft slab layer 34 is laminated on the front and rear side portions 31B and 31C and the high-hardness slab layer 33.

[0036] The relationship between the thicknesses of the base portion 31A, the latex layer 32, the high-hardness slab layer 33, and the soft slab layer 34 is such that the high-hardness slab layer 33 is the thinnest, the base portion 31A is thicker than the high-hardness slab layer 33, the soft slab layer 34 is thicker than the base portion 31A, and the latex layer 32 is thicker than the soft slab layer 34. In this embodiment, the ratio of the thicknesses of the base portion 31A, the latex layer 32, the high-hardness slab layer 33, and the soft slab layer 34 is 2:6:1:4.

[0037] The skin material 40 has a surface layer 41 made of fabric, leather, etc., and a back layer 42 made of a sponge-like padding material. The surface layer 41 has a seating surface 41A for supporting the occupant. The back layer 42 is in contact with the urethane layer 31 and the soft slab layer 34. The skin material 40 has a plurality of hooks 43 at its periphery.

[0038] The skin material 40 is attached to the cushion frame F1 by engaging a plurality of hooks 43 with the cushion frame F1 in a state of being covered on the cushion pad 30. Between the seating surface 41A of the skin material 40 and the base portion 31A, the above-described latex layer 32, high-hardness slab layer 33, and soft slab layer 34 are arranged in this order from the bottom.

[0039] According to the above, the following effects can be obtained in the present embodiment. Since the latex layer 32 made of latex foam is arranged between the skin material 40 and the urethane layer 31, the cushion pad 30 can be made into a structure with a large amount of deflection under a low load and difficult to feel a bottoming feeling. In addition, the body pressure can be dispersed and supported by the elasticity of the latex layer 32, and the bottoming feeling (feeling that the bottom suddenly becomes hard after sinking) when sitting can be reduced.

[0040] Since the left and right side portions 31D, 31E harder than the latex layer 32 sandwich the layers 32 to 34 from the left and right directions, it is possible to preferably suppress the layers 32 to 34 from shifting to the left and right.

[0041] Since the left and right side portions 31D, 31E are integrally formed with the base portion 31A of the urethane layer 31, the structure of the cushion pad 30 can be simplified as compared with, for example, the case where the left and right side portions and the base portion of the urethane layer are separate members.

[0042] [Second Embodiment] Next, a second embodiment of the present invention will be described in detail with reference to the drawings as appropriate. Since this embodiment is obtained by changing a part of the structure of the cushion pad 30 according to the above-described first embodiment, the same reference numerals will be given to the same components as those in the first embodiment, and the description thereof will be omitted.

[0043] As shown in FIG. 5, the cushion pad 130 according to the second embodiment has substantially the same layers 31 to 34 as those in the first embodiment, and further includes a resin spring layer 35 as an example of a third pad layer, a profile layer 36 as an example of a fourth pad layer, and a low resilience slab layer 37.

[0044] The resin spring layer 35, the profile layer 36, and the low resilience slab layer 37 are disposed between the high hardness slab layer 33 and the soft slab layer 34. Specifically, the layers 31 to 37 are arranged in the order of the base portion 31A of the urethane layer 31, the latex layer 32, the high hardness slab layer 33, the resin spring layer 35, the profile layer 36, the low resilience slab layer 37, and the soft slab layer 34 from the bottom.

[0045] That is, the resin spring layer 35 is disposed between the latex layer 32 and the seating surface 41A of the skin material 40. The high hardness slab layer 33 is disposed between the latex layer 32 and the resin spring layer 35. The profile layer 36 is disposed between the resin spring layer 35 and the seating surface 41A of the skin material 40. The soft slab layer 34 is disposed between the profile layer 36 and the seating surface 41A of the skin material 40. The low resilience slab layer 37 is disposed between the profile layer 36 and the soft slab layer 34.

[0046] The resin spring layer 35 is composed of a network resin structure in which synthetic resin fibers are intricately entangled in a three-dimensional manner. The resin spring layer 35 has a greater elastic force than the urethane layer 31. The resin spring layer 35 is laminated on the high hardness slab layer 33.

[0047] The profile layer 36 is made of profile urethane. The profile urethane is a urethane foam having a corrugated surface composed of a plurality of convex portions 36A. The plurality of convex portions 36A protrude toward the occupant. The profile layer 36 is laminated on the resin spring layer 35.

[0048] The latex layer 32, the high-hardness slab layer 33, the resin spring layer 35, and the profile layer 36 are sandwiched in the front-rear direction by the front and rear side portions 31B, 31C.

[0049] The low-rebound slab layer 37 is a urethane foam having a lower resilience than the urethane foam constituting the urethane layer 31. Specifically, the density of the urethane foam constituting the low-rebound slab layer 37 is smaller than the density of the urethane foam constituting the urethane layer 31 and larger than the density of the urethane foam constituting the soft slab layer 34. That is, the relationship of the densities of the urethane foams is such that soft slab layer 34 < low-rebound slab layer 37 < urethane layer 31 < high-hardness slab layer 33.

[0050] The low-rebound slab layer 37 is laminated on the front and rear side portions 31B, 31C and the profile layer 36. The soft slab layer 34 is laminated on the low-rebound slab layer 37.

[0051] The relationship of the thicknesses of the respective layers 31(31A) to 37 is such that the soft slab layer 34, the low-rebound slab layer 37, and the high-hardness slab layer 33 are the thinnest, the base portion 31A and the resin spring layer 35 are thicker than the high-hardness slab layer 33, the profile layer 36 is thicker than the resin spring layer 35, and the latex layer 32 is thicker than the profile layer 36. In the present embodiment, the thickness ratio of the base portion 31A, the latex layer 32, the high-hardness slab layer 33, the resin spring layer 35, the profile layer 36, the low-rebound slab layer 37, and the soft slab layer 34 is 2:6:1:2:3.5:1:1.

[0052] As described above, according to the second embodiment, in addition to achieving the same effects as the first embodiment, having the profile layer 36 can improve the body pressure dispersion. Also, having the resin spring layer 35 can give the cushion pad 130 an appropriate resilience.

[0053] Note that the present invention is not limited to the above-described embodiments, and can be used in various forms as exemplified below. In the following description, members having substantially the same structure as those in the above-described embodiments are denoted by the same reference numerals, and the description thereof is omitted.

[0054] The positional relationship among the latex layer 32, the resin spring layer 35, and the profile layer 36 is not limited to the second embodiment, and can be arbitrarily set. Also, the cushion pad may have at least one of the latex layer 32, the resin spring layer 35, and the profile layer 36.

[0055] For example, like the cushion pad 230 shown in FIG. 6, it may be configured to have the resin spring layer 35 and the profile layer 36 among the latex layer 32, the resin spring layer 35, and the profile layer 36, and not have the latex layer 32. Specifically, the cushion pad 230 shown in FIG. 6 has a base portion 31A so as to fill the region where the latex layer 32 of the cushion pad 130 shown in FIG. 5 was disposed. In this form, the resin spring layer 35 corresponds to the second pad layer, and the profile layer 36 corresponds to the third pad layer. Note that in the form shown in FIG. 6, by interchanging the positions of the resin spring layer 35 and the profile layer 36, the second pad layer may be the profile layer 36, and the third pad layer may be the resin spring layer 35.

[0056] In each of the above-described embodiments, the S spring 14 is exemplified as a member for supporting the cushion pad, but the present invention is not limited thereto, and for example, the cushion pad may be supported by a wire frame or the like.

[0057] In each of the above embodiments, the cushion frame F1 was exemplified as an example of the seat frame. However, the present invention is not limited thereto, and the seat frame may be, for example, the back frame F2.

[0058] In each of the above embodiments, the vehicle seat S mounted on an automobile was exemplified as the seat. However, the present invention is not limited thereto, and it may be a seat for a vehicle mounted on a vehicle other than an automobile, such as a railway vehicle, a ship, or an aircraft. Further, the seat is not limited to a vehicle seat, and may be, for example, a seat used at home.

[0059] Each element described in the above-described embodiments and modified examples may be arbitrarily combined and implemented.

Description of Reference Numerals

[0060] 30 Cushion pad 31 Urethane layer 32 Latex layer 40 Skin material F1 Cushion frame S Vehicle seat

Claims

1. A seat comprising a seat frame, a pad covering the seat frame, and a skin material covering the pad, wherein the pad has a first pad layer made of urethane foam, a second pad layer disposed between the first pad layer and the skin material, and a third pad layer disposed between the second pad layer and the skin material, the second pad layer is made of latex foam, and the third pad layer is made of profile urethane or a reticulated resin structure, characterized by the seat.

2. The pad has a fourth pad layer disposed between the third pad layer and the skin material, the third pad layer is made of a reticulated resin structure, and the fourth pad layer is made of profile urethane, characterized by the seat according to claim 1.

3. The pad has a high-hardness slab layer made of urethane foam harder than the urethane foam constituting the first pad layer, disposed between the second pad layer and the third pad layer, characterized by the seat according to claim 2.

4. The pad has a soft slab layer made of urethane foam softer than the urethane foam constituting the first pad layer, disposed between the fourth pad layer and the skin material, characterized by the seat according to claim 3.

5. The pad has a low-rebound slab layer made of urethane foam having a lower resilience than the urethane foam constituting the first pad layer, disposed between the fourth pad layer and the soft slab layer, characterized by the seat according to claim 4.

6. An S spring spanned across the seat frame, comprising an S spring supporting the first pad layer, characterized by the seat according to any one of claims 1 to 5.

7. The pad has left and right side portions sandwiching the second pad layer from the left and right directions, and the side portions are harder than the second pad layer, characterized by the seat according to any one of claims 1 to 6.

8. The left and right side portions and the first pad layer are integrally formed, characterized by the seat according to claim 7.

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