Sheet and manufacturing method thereof

Abstract

To provide a seat capable of improving moldability of a headrest pad, and to provide a manufacturing method thereof.SOLUTION: In a seat having a headrest S3, the headrest S3 includes: a case member 40 for storing an apparatus (blower 80); and a headrest pad P3 comprising a resin foam, and adhering to the case member 40. The case member 40 has an insertion hole 40H for allowing passage of a nozzle for injecting a resin foam material, on a rear end region. A manufacturing method of the seat includes the steps of: setting the case member 40 in a mold; passing the nozzle into the insertion hole 40H: and injecting the resin foam material from the nozzle into the mold.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a seat with a headrest and a method for manufacturing the same. [Background technology]

[0002] A known headrest includes a pillar frame attached to a seat back, a core material, a cover covering a portion of the pillar frame and the core material, and a cushion material formed between the core material and the cover (see Patent Document 1). In this technology, the core material has an injection channel penetrating vertically near the center. The headrest is manufactured by fixing the core material to the pillar frame, inserting the core material and the pillar frame into a skin material, setting the skin material, core material, and pillar frame in a mold, inserting an injection nozzle into one end of the injection channel, and injecting a foaming material from the injection nozzle into the skin material to form the cushion material. In the cushion material forming process, the foaming material injected from the injection nozzle into the injection channel is agitated by an agitator, and portions of the foaming material injected into one end and the other end of the injection channel are dispersed, forming the cushion material in the gap between the outer surface of the core material and the inner surface of the skin material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-123302 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, when a headrest cushioning material (headrest pad) is formed by injecting a foaming resin material from a nozzle, it is desirable that the headrest pad has good formability even without stirring.

[0005] Therefore, an object of the present invention is to provide a seat that can improve the formability of a headrest pad, and a manufacturing method thereof. [Means for solving the problem]

[0006] A seat for achieving the above-mentioned object is a seat equipped with a headrest, the headrest comprising a case member for accommodating equipment and a headrest pad made of foamed resin adhered to the case member, the case member having an insertion hole in the front, rear, left or right end region for passing a nozzle for injecting the foamed resin material.

[0007] With this configuration, when molding the headrest, the foaming resin material can be injected into the mold from a position offset to the front, rear, left, or right with respect to the center of the case member, so that the foaming resin material can flow from the inner surface of the front, rear, left, or right side of the mold, through the bottom surface of the mold, and along the inner surface on the opposite side to the front, rear, left, or right. This makes it possible to prevent air bubbles from forming in the headrest pad, thereby improving the moldability of the headrest pad.

[0008] The insertion hole may be provided at a rear end of the case member.

[0009] With this, when a load is applied to the headrest from the front, the force is less likely to be applied to the vicinity of the insertion hole of the case member, so that deformation of the vicinity of the insertion hole of the case member can be suppressed.

[0010] The headrest may include a headrest frame to which the case member is attached, and the insertion hole may be disposed behind the headrest frame.

[0011] With this, when a load is applied to the headrest from the front, the load can be received by the headrest frame, and therefore deformation of the vicinity of the insertion hole of the case member can be further suppressed.

[0012] The headrest frame may have a pair of pillar portions spaced apart from each other on the left and right, and the insertion hole may be disposed between the pair of pillar portions in the left-right direction.

[0013] This allows the insertion hole to be disposed near the center of the headrest in the left-right direction, thereby improving the formability of the headrest pad.

[0014] The case member may have an upper cover member and a lower cover member attached to the upper cover member, and the insertion hole may be provided in the upper cover member.

[0015] This allows for greater freedom in manufacturing the headrest, since when molding the headrest, only the upper cover member of the case member can be set in the mold and the foaming resin material can be injected into the mold through a nozzle inserted into the insertion hole.

[0016] In addition, the upper cover member may have a storage section that is concave from bottom to top and an edge section provided in front, rear, left or right of the storage section, and the insertion hole may be provided in the edge section.

[0017] With this, the housing portion in which the device is housed has no insertion hole, so that the rigidity of the housing portion can be ensured.

[0018] The insertion hole may be disposed at a position that does not overlap with the device when viewed from the direction in which the insertion hole penetrates.

[0019] This allows the nozzle to be passed through the insertion hole even when the device is housed in the case member, thereby improving the degree of freedom when manufacturing the headrest.

[0020] The case member may have a plurality of the end regions, and among the plurality of end regions, the end region in which the insertion hole is provided may be located higher than the other end regions.

[0021] The headrest may also include a headrest frame to which the case member is attached, and a support member that supports the head of the seated occupant and is fixed to the headrest frame, and the insertion hole may be positioned so as not to overlap with the support member when viewed from the direction in which the insertion hole passes through.

[0022] With this, when the nozzle is passed through the insertion hole and the foaming resin material is injected into the mold, the flow of the foaming resin material is not obstructed by the support member, so the headrest pad can be molded well.

[0023] The headrest may also include a seat cushion and a seat back, the seat cushion including a seat cushion frame, a seat cushion pad covering the seat cushion frame, and a seat cushion skin covering the seat cushion frame and the seat cushion pad, and the seat back may include a seat back frame, a seat back pad covering the seat back frame, and a seat back skin covering the seat back frame and the seat back pad.

[0024] Furthermore, a method for manufacturing a seat to achieve the above-mentioned object is a method for manufacturing a seat equipped with a headrest, comprising a case member for accommodating equipment, and a headrest pad made of foamed resin in close contact with the case member, the case member having an insertion hole in the front, rear, left or right end region for passing a nozzle for injecting the foamed resin material, the method comprising the steps of: setting the case member in a mold; passing the nozzle through the insertion hole; and injecting the foamed resin material into the mold from the nozzle.

[0025] According to this method, the foaming resin material can be injected into the mold from a position offset to the front, rear, left, or right with respect to the center of the case member, so that the foaming resin material can flow from the inner surface of the front, rear, left, or right side of the mold, through the bottom of the mold, and along the inner surface on the opposite side to the front, rear, left, or right side. This makes it possible to prevent air bubbles from forming in the headrest pad, thereby improving the formability of the headrest pad. [Effects of the Invention]

[0026] According to the present invention, the formability of the headrest pad can be improved.

[0027] Furthermore, by providing the insertion hole at the rear end of the case member, deformation of the vicinity of the insertion hole of the case member can be suppressed.

[0028] Furthermore, by arranging the insertion hole behind the headrest frame, deformation of the vicinity of the insertion hole of the case member can be further suppressed.

[0029] Furthermore, by arranging the insertion hole at a position between the pair of pillar portions of the headrest frame in the left-right direction, it is possible to improve the formability of the headrest pad.

[0030] Furthermore, by providing the insertion holes in the upper cover member of the case member, the degree of freedom in manufacturing the headrest can be improved.

[0031] Furthermore, by providing the insertion holes in the edge portion of the upper cover member, the rigidity of the storage portion can be ensured.

[0032] Furthermore, by arranging the insertion hole at a position that does not overlap with the device when viewed from the direction of penetration, the degree of freedom in manufacturing the headrest can be improved.

[0033] Furthermore, by arranging the insertion holes at positions that do not overlap with the support members when viewed from the direction of penetration, the headrest pad can be molded well. [Brief explanation of the drawings]

[0034] [Figure 1] FIG. 1 is a perspective view of a seat according to an embodiment. [Figure 2] FIG. 2 is a perspective view showing a seat cushion frame, a seat back frame, a seat cushion pad, and a seat back pad. [Figure 3] FIG. 2 is a perspective view showing the internal structure of the headrest. [Figure 4] FIG. [Figure 5] FIG. 2 is a perspective view showing an upper cover member and a lower cover member that constitute a case member, a mounting member, and a blower. [Figure 6] FIG. 2 is a perspective view showing an upper cover member and an attachment member. [Figure 7] FIG. 2 is a bottom view of the upper cover member and the blower. [Figure 8] FIG. 4 is a cross-sectional view showing a case member, a mounting member, and a support member. [Figure 9] FIG. 2 is a perspective view showing a front member and a rear member that constitute a lower cover member. [Figure 10] FIG. 10 is a top view of the lower cover member and the ventilation member. [Figure 11] 11 is a cross-sectional view taken along the line XX in FIG. [Figure 12] FIG. 2 is a perspective view of the headrest frame, the case member, the mounting member, and the support member as seen from the rear. [Figure 13] 1A and 1B are diagrams illustrating a method for manufacturing a vehicle seat. [Figure 14] 13(a) and 13(b) illustrating a method for manufacturing a vehicle seat. DETAILED DESCRIPTION OF THE INVENTION

[0035] Next, an embodiment of the seat will be described. In this specification, the terms "front, back, left, right, top, bottom" and "bottom" refer to the front, back, left, right, top, bottom as seen from the perspective of a person sitting in the seat (seat occupant). 1, the seat according to the embodiment is configured as a vehicle seat to be installed in a vehicle, specifically, as a vehicle seat S to be installed in an automobile. The vehicle seat S includes a seat cushion S1, a seat back S2, and a headrest S3.

[0036] As shown in FIGS. 1 and 2, the seat cushion S1 includes a seat cushion frame F1, a seat cushion pad P1, and a seat cushion skin SK1. The seat cushion frame F1 is a member that constitutes the frame of the seat cushion S1, and has a pair of left and right seat cushion side frames 11, a front frame 12, and a rear frame 13.

[0037] The front frame 12 connects the front portions of the seat cushion side frames 11 together, and the rear frame 13 connects the rear portions of the seat cushion side frames 11 together. A support member 15 that bears a load is disposed between the seat cushion side frames 11. The support member 15 has a plurality of metal wires that extend forward and backward while bending alternately left and right, and a resin portion molded integrally with the metal wires, and is disposed in a state spanning the front frame 12 and the rear frame 13.

[0038] The seat cushion pad P1 is a member that covers the seat cushion frame F1, and is made of foamed resin such as urethane foam. The seat cushion cover SK1 is a member that covers the seat cushion frame F1 and the seat cushion pad P1, and is made of leather, fabric, or the like.

[0039] The seat back S2 includes a seat back frame F2, a seat back pad P2, and a seat back skin SK2. The seat back frame F2 is a member that constitutes the frame of the seat back S2, and has a pair of lower side frames 22, a pipe frame 23, a lower frame 24, and a bridging frame 25.

[0040] The pipe frame 23 has a pair of left and right upper side frames 23A and an upper frame 23B connecting the upper ends of the upper side frames 23A. The upper side frames 23A are connected to the lower side frames 22 and, together with the lower side frames 22, form seatback side frames 21, which are the left and right frames of the seatback S2. A pair of left and right holders 26 that hold headrest guides (not shown) are fixed to the upper frame 23B. The lower frame 24 connects the lower parts of the seatback side frames 21, and a bridging frame 25 is disposed below the upper frame 23B and connects the upper parts of the seatback side frames 21. A plate-shaped pressure-receiving member 27 that receives a load is disposed between the seatback side frames 21.

[0041] The seat back pad P2 is a member that covers the seat back frame F2 and is made of foamed resin such as urethane foam. The seat back cover SK2 is a member that covers the seat back frame F2 and the seat back pad P2, and is made of leather, fabric, or the like.

[0042] As shown in FIGS. 3 and 4, the headrest S3 includes a headrest frame F3, a headrest pad P3, and a headrest skin SK3. The headrest frame F3 is made of, for example, a metal pipe, and has a pair of left and right pillar portions 31 and a connecting portion 32 that connects the upper ends of the pillar portions 31 together.

[0043] The pillar portion 31 extends vertically. Specifically, the pillar portion 31 has a first portion 31A, a second portion 31B, and a third portion 31C. The first portion 31A extends downward from the left and right ends of the connecting portion 32. The second portion 31B extends downward from the lower end of the first portion 31A so as to be positioned laterally outward and rearward as it goes downward. The third portion 31C extends downward from the lower end of the second portion 31B. The pair of pillar portions 31 are arranged with a gap between them on the left and right.

[0044] The headrest pad P3 is a member that covers the upper part of the headrest frame F3. Specifically, the headrest pad P3 covers the connecting portion 32 and the upper ends of the first portion 31A, the second portion 31B, and the third portion 31C of the pair of pillar portions 31. The headrest pad P3 is made of foamed resin such as urethane foam, and is formed in close contact with the upper part of the headrest frame F3, the outer surfaces of the case member 40 (described later), and the inner surface of the headrest skin SK3.

[0045] The headrest covering SK3 is a member that covers the headrest pad P3 and the like, and is made of leather, fabric, or the like.

[0046] The headrest S3 is configured to blow out temperature-controlled air from ventilation openings 71C located at the lower front side toward the neck area of ​​the seated occupant (see the dashed arrows in FIG. 4). The headrest S3 further includes a case member 40, an attachment member 50, a support member 60, and a ventilation member 70. The case member 40 is attached to the headrest frame F3 via the attachment member 50.

[0047] As shown in Fig. 4, the case member 40 is a member that houses equipment provided inside the headrest S3. In this embodiment, the equipment housed in the case member 40 is a blower 80. The blower 80 is, for example, a sirocco fan. The blower 80 has a heater (not shown) inside, near the outlet from which air is blown out, or near the inlet from which air is drawn in, for heating air.

[0048] As shown in FIG. 5, blower 80 has a blower main body 81 equipped with a fan, motor, heater, etc. (not shown), and three mounting portions 82 protruding forward, backward, and to the left from blower main body 81. Blower main body 81 has an intake port 81A (see FIG. 7) for drawing in air and an outlet port 81B for blowing out air. Blower 80 is disposed within headrest S3 with intake port 81A facing downward and outlet port 81B facing forward. Mounting portion 82 has a through-hole 83 formed therein through which a tapping screw 92 for fixing blower 80 to case member 40 passes.

[0049] The case member 40 has an upper cover member 100 and a lower cover member 200 attached to the upper cover member 100. By attaching the lower cover member 200 to the upper cover member 100, a space for accommodating the blower 80 and an air passage are formed inside the case member 40. The case member 40 also has an insertion hole 40H.

[0050] The upper cover member 100 is a member that covers the blower 80 from above. The blower 80 is attached to the upper cover member 100. As shown in FIG. 6 , the upper cover member 100 has an accommodation section 110 that accommodates the blower 80, and an edge section 120 that serves as an end region of the case member 40. The storage section 110 is a portion that is recessed from bottom to top (see also FIG. 8).

[0051] The edge portion 120 is provided so as to surround the storage portion 110. The edge portion 120 has a front edge portion 121, a rear edge portion 122, a left edge portion 123, and a right edge portion 124 as a plurality of end regions.

[0052] The front edge 121 is a portion of the edge 120 that is provided in front of the storage section 110. More specifically, the front edge 121 extends forward from the storage section 110, and the end opposite to the side connected to the storage section 110 is bent and extends upward. The rear edge 122 is a portion of the edge 120 that is provided behind the storage section 110. More specifically, the rear edge 122 extends rearward from the storage section 110, and the end opposite to the side connected to the storage section 110 is bent and extends upward.

[0053] The left edge 123 is a portion of the edge 120 provided to the left of the storage section 110. More specifically, the left edge 123 extends leftward from the storage section 110, and the end opposite to the side connected to the storage section 110 is bent and extends upward. The left edge 123 is connected to the front edge 121 and the rear edge 122 and is formed integrally with them.

[0054] The right edge 124 is a portion of the edge 120 that is provided to the right of the storage section 110. More specifically, the right edge 124 extends to the right from the storage section 110, and the end opposite to the side connected to the storage section 110 is bent and extends upward. The right edge 124 is connected to the front edge 121 and the rear edge 122 and is formed integrally with them.

[0055] The edges 121-124 provided to surround the storage section 110 are connected and integrally formed, thereby improving the rigidity of the upper cover member 100. Furthermore, the end of each of the edges 121-124 opposite to the side connected to the storage section 110 is bent and extends upward, thereby improving the rigidity of the upper cover member 100.

[0056] The rear end portions of the left edge portion 123 and the right edge portion 124 are each formed in a substantially circular shape when viewed from above, and have pillar insertion holes 125 through which the pillar portions 31 of the headrest frame F3 pass (see also FIG. 7).

[0057] The insertion hole 40H is a through-hole for passing a nozzle 320 (see FIG. 14) that injects a foam resin material that forms the headrest pad P3. The insertion hole 40H is a through-hole that penetrates vertically and is formed in a substantially rectangular shape that is long in the left-right direction. The insertion hole 40H is provided in the rear end region of the case member 40. In other words, the insertion hole 40H is provided in the rear end portion of the case member 40. More specifically, the insertion hole 40H is provided in the rear edge portion 122 of the upper cover member 100.

[0058] 7, the insertion hole 40H is provided in the center of the rear edge portion 122 in the left-right direction, and is disposed in a position between the pair of pillar insertion holes 125 in the left-right direction. As a result, the insertion hole 40H is disposed in a position between the pair of pillar portions 31 that pass through the pillar insertion hole 125 in the left-right direction. Furthermore, because the insertion hole 40H is provided in the rear edge portion 122 that is provided behind the accommodating portion 110, the insertion hole 40H is disposed in a position that does not overlap with the blower 80 accommodated in the accommodating portion 110 when viewed from the direction in which the insertion hole 40H penetrates.

[0059] 8, the insertion hole 40H is disposed behind the headrest frame F3. Specifically, the insertion hole 40H is disposed behind the rear end E4 of the headrest frame F3. The insertion hole 40H is disposed at a position that does not overlap with the headrest frame F3, the mounting member 50, and the support member 60 when viewed from the direction in which the insertion hole 40H penetrates.

[0060] Of the multiple end regions on the front, rear, left, and right sides of the case member 40, the end region in which the insertion hole 40H is provided is located higher than the other end regions. Specifically, the rear edge portion 122 in which the insertion hole 40H is provided is located higher than the front edge portion 121, the left edge portion 123, and the right edge portion 124. The case member 40 is disposed at an angle so that the rear end portion is located higher than the front end portion, and therefore the rear edge portion 122 is located higher than the front edge portion 121, the left edge portion 123, and the right edge portion 124.

[0061] As shown in FIG. 6, the upper cover member 100 has a positioning portion 130, four ribs 140, and three through holes 151 to 153 through which the tapping screws 91A to 91C pass. The positioning portion 130 is a portion for determining the position of the case member 40 relative to the mounting member 50, and engages with an engaging portion 53 (through hole) (described later) of the mounting member 50. The positioning portion 130 is formed in a convex shape that protrudes upward from near the center of the upper wall of the accommodating portion 110.

[0062] The rib 140 is a portion that abuts against the mounting member 50 when the case member 40 is attached to the mounting member 50 (see FIG. 8). The rib 140 protrudes upward from the upper wall of the upper cover member 100 toward the mounting member 50 and extends in the front-to-rear direction. The rib 140 includes a pair of left and right outer ribs 141 and a pair of left and right inner ribs 142.

[0063] The pair of outer ribs 141 are arranged with a gap between them on the left and right. The pair of outer ribs 141 are arranged near the center in the front-to-rear direction of the upper wall of the storage section 110 and near the end in the left-to-right direction. The pair of outer ribs 141 are arranged on the left and right sides of the positioning section 130 so as to sandwich the positioning section 130 therebetween. In other words, the positioning section 130 is arranged between the pair of outer ribs 141 lined up on the left and right.

[0064] The pair of inner ribs 142 are arranged at a distance from each other on the left and right sides. The pair of inner ribs 142 are arranged near the center of the upper wall of the storage section 110 and extend rearward from the positioning section 130. The pair of inner ribs 142 are arranged between the pair of outer ribs 141.

[0065] The outer rib 141 extends further in the front-rear direction than the inner rib 142. Specifically, the rear ends of the outer rib 141 and the inner rib 142 are located at approximately the same position in the front-rear direction. On the other hand, the outer rib 141 extends forward of the positioning portion 130, and the front end of the outer rib 141 is located forward of the front end of the inner rib 142 in the front-rear direction.

[0066] The through holes 151 to 153 are generally circular through holes that penetrate vertically. The through holes 151 and 152 are arranged on the left and right sides of the positioning portion 130 so as to sandwich the positioning portion 130. In other words, the positioning portion 130 is arranged between the two through holes 151 and 152 that are lined up on the left and right. The through holes 151 and 152 are also arranged between a pair of outer ribs 141. More specifically, the through hole 151 is arranged between the positioning portion 130 and the left outer rib 141, and the through hole 152 is arranged between the positioning portion 130 and the right outer rib 141.

[0067] The through hole 153 is disposed behind the positioning portion 130. The through hole 153 is also disposed behind the ribs 140 (141, 142). The through hole 153 is also disposed between the pair of outer ribs 141 in the left-right direction. The through hole 153 is also disposed between the pair of inner ribs 142 in the left-right direction.

[0068] As shown in FIG. 7, the upper cover member 100 further has three device mounting portions 160 for mounting the blowers 80 and four lower cover mounting portions 170 for mounting the lower cover member 200.

[0069] The device mounting portion 160 and the lower cover mounting portion 170 are formed in a generally cylindrical shape that protrudes downward from the upper wall of the storage portion 110. One device mounting portion 160 is provided at the front, rear, and left of the fan body 81, corresponding to the three mounting portions 82 of the fan 80. One lower cover mounting portion 170 is provided near each of the four corners of the storage portion 110.

[0070] The upper cover member 100 further has reinforcing ribs 161 that protrude from the side surfaces of the device mounting portions 160 toward the outside in the radial direction of the device mounting portions 160 and have their upper ends connected to the upper wall of the accommodating portion 110. Three reinforcing ribs 161 are provided for each device mounting portion 160. The presence of the reinforcing ribs 161 can improve the rigidity of the device mounting portions 160.

[0071] The upper cover member 100 also has reinforcing ribs 171 that protrude from the side surfaces of the lower cover attachment portions 170 toward the outside in the radial direction of the lower cover attachment portions 170 and have their upper ends connected to the upper wall of the accommodating portion 110. Three reinforcing ribs 171 are provided on each lower cover attachment portion 170. The presence of the reinforcing ribs 171 can improve the rigidity of the lower cover attachment portions 170.

[0072] 5, the lower cover member 200 is a member that covers the fan 80 from below. The lower cover member 200 has a structure divided into a front and a rear part. More specifically, the lower cover member 200 has a front member 210 and a rear member 220 that supports the front member 210 from the rear.

[0073] As shown in FIG. 9, the front member 210 has a plate-shaped front base portion 211, five first claw portions 212, and four second claw portions 213. The front base portion 211 has a ventilation member attachment portion 211A at the left-right center of the front end portion. The ventilation member attachment portion 211A is the portion where the ventilation member 70 is disposed, and has a shape that is recessed from top to bottom. One through-hole 211B is formed at each of the left and right ends of the ventilation member attachment portion 211A, through which a tapping screw 94 (see FIG. 11) passes to fix the ventilation member 70 to the front member 210.

[0074] The first claw portions 212 are generally L-shaped portions that protrude upward from the rear of the front base portion 211 and extend rearward when viewed from the left and right. The five first claw portions 212 are arranged spaced apart from each other on the left and right. In this embodiment, the intervals between adjacent first claw portions 212 are generally the same.

[0075] The second claw portions 213 are portions that protrude upward or downward from the rear end portion of the front base portion 211 on the same side as the first claw portions 212. Specifically, the second claw portions 213 protrude upward from the rear end portion of the front base portion 211. The front surface of the second claw portions 213 is shaped to be approximately perpendicular to the upper surface of the front base portion 211, and the rear surface of the second claw portions 213 is shaped to be inclined so that the upper surface is positioned further forward (see FIG. 11). One second claw portion 213 is provided between each pair of adjacent first claw portions 212 in the left-right direction.

[0076] The rear member 220 has a plate-shaped rear base portion 221, a pair of left and right pillar accommodating portions 222, a pair of left and right connecting portions 223, a first rib 224, two second ribs 225, three third ribs 226, four engagement holes 227, an air intake portion 228, and a through hole 229. The rear base portion 221 is a portion that is connected to the front member 210 .

[0077] The pillar accommodating portions 222 are portions through which the pillar portions 31 of the headrest frame F3 pass, and one is provided on each side of the rear member 220. The pillar accommodating portions 222 have a shape that surrounds the pillar portion 31 from the front and rear. More specifically, the pillar accommodating portion 222 has cutouts 222A that are open on the left and right outer sides and are used to pass the pillar portion 31 through, thereby forming a generally U-shape that is open on the left and right outer sides. The pillar accommodating portions 222 surround the pillar portion 31 that passes through the cutouts 222A from the front, left and right inner sides, and rear (see FIG. 10).

[0078] The pillar accommodating portion 222 is positioned at a position offset upward with respect to the rear base portion 221. In other words, the rear base portion 221 is positioned at a position offset downward with respect to the pillar accommodating portion 222.

[0079] The connection portions 223 are portions that connect the rear base portion 221 and the pillar accommodating portion 222, and are provided one on each side of the rear member 220. The connection portions 223 are inclined so that the closer they are to the rear base portion 221 from the pillar accommodating portion 222, the more they are positioned radially outward of the pillar accommodating portion 222 (pillar portion 31).

[0080] 10, the connecting portion 223 has a generally U-shape that is open on the left and right outer sides, and the left and right outer ends 223A of the portion located on the front side of the pillar portion 31 and the left and right outer ends 223B of the portion located on the rear side of the pillar portion 31 are located at the same position in the left-right direction. Specifically, the ends 223A and 223B of the left connecting portion 223 are located at the same position in the left-right direction, and the ends 223A and 223B of the right connecting portion 223 are located at the same position in the left-right direction (see imaginary lines).

[0081] The first rib 224 is a rib that protrudes upward from the rear base portion 221 and extends left and right so as to connect the pair of pillar accommodating portions 222. In this embodiment, the left and right ends of the first rib 224 are connected to the left and right connecting portions 223.

[0082] The second rib 225 is a rib that protrudes upward from the rear base portion 221 and extends in the front-rear direction so as to connect to the pillar accommodating portion 222. In this embodiment, the rear end of the second rib 225 is connected to the connecting portion 223. In other words, the second rib 225 is provided so as to extend forward from the connecting portion 223. The two second ribs 225 are arranged spaced apart on the left and right.

[0083] The third rib 226 is a rib that protrudes upward from the rear base portion 221 and extends in the front-rear direction so as to connect to the first rib 224. In this embodiment, the rear end of the third rib 226 is connected to the first rib 224. In other words, the third rib 226 is provided so as to extend forward from the first rib 224. The three third ribs 226 are arranged with a gap between them on the left and right. The three third ribs 226 are also arranged between two second ribs 225.

[0084] The middle third rib 226 of the three third ribs 226 is disposed near the center in the left-right direction of the rear member 220. In this embodiment, the intervals between adjacent third ribs 226 and the intervals between adjacent second ribs 225 and third ribs 226 are substantially the same.

[0085] The engagement holes 227 are holes that penetrate vertically and engage with the second claw portions 213 when the front member 210 is connected to the rear member 220. The engagement holes 227 are formed in a generally rectangular shape that is long in the left-right direction. One engagement hole 227 is provided between adjacent second ribs 225 and third ribs 226, and one engagement hole 227 is provided between adjacent third ribs 226.

[0086] 9, air intake portion 228 is provided to protrude upward from the rear end portion of rear base portion 221. Air intake portion 228 has intake port 228A (see FIG. 11) for taking air into case member 40.

[0087] The through-hole 229 is a hole for passing a harness (not shown) connected to the blower 80. The through-hole 229 is disposed between the first rib 224 and the air intake portion 228, and between the pair of pillar accommodating portions 222. In this embodiment, the through-hole 229 is disposed to the right of the center of the rear member 220 in the left-right direction.

[0088] As shown in FIG. 5, the ventilation member 70 has a ventilation section 71, an extension section 72, and two cover member attachment sections 73 on the left and right, and is attached to the front member 210 that constitutes the lower cover member 200.

[0089] As shown in Fig. 11, ventilation section 71 has a cylindrical shape that penetrates from front to back, and has connection port 71A, ventilation passage 71B, and ventilation port 71C. Connection port 71A is an opening to which air outlet 81B of blower 80 is connected, and ventilation port 71C is an opening through which air sent out from blower 80 passes. As shown in Fig. 10, ventilation passage 71B (see dashed line) is a passage that connects connection port 71A and ventilation port 71C, and has a shape in which the distance between the left and right sides increases toward the front.

[0090] The extension portion 72 is a plate-shaped portion that extends left and right and rearward from the lower end of the ventilation portion 71 . The cover member attachment portions 73 are portions that protrude upward from the left and right ends of the extension portion 72 (see also FIG. 5), and are formed in a generally cylindrical shape that penetrates vertically.

[0091] The ventilation member 70 is provided as a separate member from the case member 40. More specifically, the ventilation member 70 is provided as a separate member from the front member 210 and the rear member 220 of the upper cover member 100 and the lower cover member 200.

[0092] As shown in FIG. 11, the ventilation member 70 is placed on the ventilation member mounting portion 211A of the front member 210 that constitutes the lower cover member 200, and is attached to the front member 210 by passing two tapping screws 94 through the through holes 211B of the front member 210 and fastening them to the cover member mounting portion 73.

[0093] As shown in FIG. 9, the lower cover member 200 further has screw insertion portions 230. Four screw insertion portions 230 are provided corresponding to the four lower cover mounting portions 170 (see FIG. 7) provided on the upper cover member 100. Each screw insertion portion 230 is a generally truncated cone-shaped portion that is recessed from bottom to top, and has a generally circular through-hole 231 that penetrates vertically through its upper wall. The four screw insertion portions 230 include two screw insertion portions 230A provided on the front member 210 and a screw insertion portion 230B provided on the rear member 220.

[0094] The screw insertion portions 230A are disposed one by one between the first claw portion 212 positioned outermost in the left-right direction and the first claw portion 212 adjacent to that first claw portion 212. The left screw insertion portion 230B is disposed behind the left screw insertion portion 230A, and the right screw insertion portion 230B is disposed behind the right screw insertion portion 230A. The screw insertion portions 230B are provided so as to connect to the corresponding left and right connection portions 223.

[0095] When assembling the lower cover member 200, the front end of the rear member 220 is inserted between the rear end of the front base portion 211 of the front member 210 and the first claw portion 212. As shown in FIG. 8, when the front member 210 is connected to the rear member 220, the rear end of the front base portion 211 and the first claw portion 212 clamp the front end of the rear base portion 221 of the rear member 220 and the front end of the corresponding third rib 226 (or second rib 225). Also, as shown in FIG. 11, when the front member 210 is connected to the rear member 220, the second claw portion 213 engages with an engagement hole 227 provided in the front end of the rear base portion 221 of the rear member 220.

[0096] 10 , a connection portion between the front member 210 and the rear member 220, where the rear end portion of the front member 210 and the front end portion of the rear member 220 overlap, is disposed in front of the pillar accommodating portion 222. Specifically, a portion of the rear member 220 that is sandwiched between the front base portion 211 and the first claw portion 212 and a portion that is engaged with the second claw portion 213 are disposed in front of the pillar accommodating portion 222.

[0097] The ventilation member 70 may be attached to the front member 210 before assembling the lower cover member 200, or may be attached to the front member 210 after assembling the lower cover member 200.

[0098] As shown in Fig. 12, the mounting member 50 is a member to which the case member 40 is attached, and is fixed to the headrest frame F3. As shown in Fig. 6, the mounting member 50 is made of, for example, a metal plate, and has a case mounting portion 51 to which the case member 40 is attached, and a pair of left and right fixing portions 52 fixed to the headrest frame F3.

[0099] The case mounting part 51 has a main body part 51A, an extension part 51B, and a reinforcing part 51C. The main body part 51A has a generally trapezoidal shape whose width increases toward the rear, and the extension part 51B extends rearward from the center in the left-right direction of the rear end of the main body part 51A. The reinforcing part 51C extends upward from the front end of the main body part 51A. The rigidity of the mounting member 50 can be improved by including the reinforcing part 51C.

[0100] The case attachment portion 51 further has an engagement portion 53 and three fixing holes 54A, 54B, and 54C. The engaging portion 53 is a through-hole that is substantially rectangular and long in the left-right direction, and is disposed near the center of the main body portion 51 A. The engaging portion 53 engages with the positioning portion 130 of the case member 40.

[0101] Fixing holes 54A, 54B, 54C are generally circular through-holes that penetrate vertically. Fixing holes 54A, 54B are arranged in main body portion 51A. More specifically, fixing holes 54A, 54B are arranged on the left and right sides of engaging portion 53 so as to sandwich engaging portion 53. In other words, engaging portion 53 is arranged between the two fixing holes 54A, 54B that are lined up on the left and right. Fixing hole 54C is arranged near the center of extension portion 51B. Fixing hole 54C is arranged behind engaging portion 53. In other words, engaging portion 53 is arranged in front of fixing hole 54C.

[0102] The fixing portions 52 are portions that extend upward from the left and right ends of the main body portion 51A of the case mounting portion 51. The left and right fixing portions 52 of the mounting member 50 are fixed to the left and right inner surfaces of the pair of pillar portions 31. More specifically, as shown in Fig. 8, the upper edges of the left and right fixing portions 52 of the mounting member 50 are fixed by welding to the left and right inner surfaces of the second portions 31B of the pair of pillar portions 31 (see welded portions W1).

[0103] The attachment member 50 is disposed below the upper end E1 of the headrest frame F3. The attachment member 50 is also disposed above the lower end E2 (see FIG. 4) of the headrest frame F3. In other words, the attachment member 50 is disposed between the upper end E1 and the lower end E2 of the headrest frame F3 in the vertical direction.

[0104] The attachment member 50 is disposed rearward of the front end E3 of the headrest frame F3. The attachment member 50 is disposed forward of the rear end E4 of the headrest frame F3. In other words, the attachment member 50 is disposed between the front end E3 and the rear end E4 of the headrest frame F3 in the front-rear direction.

[0105] The mounting member 50 is also disposed behind the front end E5 of the blower 80. The mounting member 50 is also disposed in front of the rear end E6 of the blower 80. In other words, the mounting member 50 is disposed between the front end E5 and the rear end E6 of the blower 80 in the front-rear direction.

[0106] 6, the headrest S3 further includes three tapping screws 91A, 91B, and 91C as multiple fixing members. The tapping screws 91A, 91B, and 91C are members for fixing the case member 40 to the mounting member 50. More specifically, the tapping screws 91A, 91B, and 91C are members for fixing the upper cover member 100 to the mounting member 50.

[0107] When fixing the upper cover member 100 to the mounting member 50, first, the positioning portions 130 of the upper cover member 100 are engaged with the engaging portions 53 of the mounting member 50, and the ribs 140 of the upper cover member 100 are abutted against the main body portions 51A of the case mounting portions 51 of the mounting member 50. Then, the tapping screws 91A are passed through the through holes 151 of the upper cover member 100 and fastened to the fixing holes 54A of the mounting member 50, the tapping screws 91B are passed through the through holes 152 of the upper cover member 100 and fastened to the fixing holes 54B of the mounting member 50, and the tapping screws 91C are passed through the through holes 153 of the upper cover member 100 and fastened to the fixing holes 54C of the mounting member 50, thereby fixing the upper cover member 100 to the mounting member 50.

[0108] 12, engaging portion 53 is disposed between two fixing holes 54A and 54B, and therefore is disposed between multiple, specifically, two tapping screws 91A and 91B, which are fastened to fixing holes 54A and 54B. Furthermore, engaging portion 53 is disposed in front of fixing hole 54C, and therefore is disposed in front of tapping screw 91C fastened to fixing hole 54C.

[0109] As shown in Fig. 7, the blower 80 is attached to the upper cover member 100 by passing three tapping screws 92 through the through holes 83 of the mounting portion 82 (see Fig. 5) and fastening them to the device mounting portion 160 of the upper cover member 100. As shown in Fig. 5, the lower cover member 200 is attached to the upper cover member 100 by passing four tapping screws 93 through the through holes 231 of the screw insertion portion 230 and fastening them to the lower cover mounting portion 170 of the upper cover member 100 (see Fig. 7). In this way, the case member 40 is assembled with the blower 80 housed therein, and is attached to the headrest frame F3 via the mounting member 50.

[0110] As shown in Fig. 8, the case member 40 is disposed below the upper end E1 of the headrest frame F3. The case member 40 is also disposed above the lower end E2 (see Fig. 4) of the headrest frame F3. In other words, the case member 40 is disposed between the upper end E1 and the lower end E2 of the headrest frame F3 in the up-down direction.

[0111] The support member 60 supports the head of the seated occupant from behind and is fixed to the headrest frame F3. The support member 60 is made of, for example, a metal plate, and has a shape in which the left, right, top, and bottom ends are bent rearward. The support member 60 is fixed to the headrest frame F3 above the portion to which the mounting member 50 is fixed.

[0112] Specifically, the support member 60 is fixed above the second portions 31B of the pair of pillar portions 31 to which the mounting member 50 is fixed. More specifically, the left and right ends of the support member 60 are fixed by welding to the left and right inner surfaces of the first portions 31A of the pair of pillar portions 31, which are located above the second portions 31B (see welded portion W2). In addition, the upper end of the support member 60 is fixed by welding to the lower surface of the connecting portion 32, which is located above the second portions 31B (see welded portion W3).

[0113] The mounting member 50 and the support member 60 are arranged with a gap between them. Specifically, the mounting member 50 and the support member 60 are arranged with a gap between the upper end of the reinforcing portion 51C and the lower end of the support member 60. The mounting member 50 and the support member 60 are not connected, but are provided as separate members.

[0114] Next, a description will be given of a manufacturing method of the vehicle seat S. In particular, among the manufacturing methods of the vehicle seat S, a manufacturing method of the headrest S3 will be mainly described.

[0115] First, the components of the headrest S3 are prepared. Specifically, as shown in Fig. 4, the headrest frame F3, mounting member 50, support member 60, upper cover member 100, blower 80, headrest skin SK3, ventilation member 70, front member 210, rear member 220, etc. are prepared.

[0116] Next, the mounting member 50 and the support member 60 are fixed to the headrest frame F3. Specifically, as shown in Fig. 8, the left and right fixing portions 52 of the mounting member 50 are fixed to the second portions 31B of the pair of pillar portions 31 of the headrest frame F3 by welding. Furthermore, the left and right ends of the support member 60 are fixed to the first portions 31A of the pair of pillar portions 31 by welding, and the upper end of the support member 60 is fixed to the connecting portion 32 by welding. The order in which the mounting member 50 and the support member 60 are fixed to the headrest frame F3 is arbitrary.

[0117] Next, the upper cover member 100 is attached to the mounting member 50 fixed to the headrest frame F3. Specifically, as shown in Fig. 12, first, the pillar portions 31 of the headrest frame F3 are passed through the left and right pillar insertion holes 125 of the upper cover member 100, the positioning portions 130 of the upper cover member 100 are engaged with the engaging portions 53 of the mounting member 50, and the ribs 140 of the upper cover member 100 are abutted against the case mounting portions 51 of the mounting member 50. Thereafter, the upper cover member 100 is attached to the mounting member 50 by passing tapping screws 91A to 91C through the through holes 151 to 153 (see Fig. 6) of the upper cover member 100 and fastening them to the fixing holes 54A to 54C of the mounting member 50.

[0118] Next, the blower 80 is attached to the upper cover member 100. Specifically, as shown in Fig. 7, three tapping screws 92 are passed through the through-holes 83 (see Fig. 5) provided in the attachment portion 82 of the blower 80 and fastened to the equipment attachment portion 160 of the upper cover member 100, thereby attaching the blower 80 to the upper cover member 100.

[0119] Next, the headrest pad P3 is formed. More specifically, first, as shown in FIG. 13(a), the headrest skin SK3 is set in a mold 310 for molding the headrest pad P3.

[0120] 13(b), the case member 40 and other components are set in the mold 310 in which the headrest skin SK3 has been set. Specifically, an assembly of the headrest frame F3, the mounting member 50, the support member 60, and the upper cover member 100 that constitutes the case member 40 is held by a jig (not shown), and a part of the headrest frame F3, the mounting member 50, the support member 60, and the upper cover member 100 are placed in the mold 310.

[0121] Next, as shown in Fig. 14(a), a nozzle 320 for injecting a foam resin material for forming the headrest pad P3 is inserted through the insertion hole 40H of the upper cover member 100. Then, as shown in Fig. 14(b), the foam resin material (foam resin material M) is injected into the mold 310 from the nozzle 320.

[0122] When the foaming resin material M injected into the mold 310 hardens and the headrest pad P3 is formed, the molded product including the headrest frame F3, upper cover member 100, headrest pad P3, and headrest skin SK3 is removed from the mold 310.

[0123] Next, the lower cover member 200 is attached to the upper cover member 100 . More specifically, first, the ventilation member 70 is attached to the front member 210 that constitutes the lower cover member 200. Specifically, as shown in Fig. 11 , the ventilation member 70 is placed on the ventilation member attachment portion 211A of the front member 210, and two tapping screws 94 are passed through the through holes 211B provided in the front member 210 and fastened to the cover member attachment portion 73 of the ventilation member 70, thereby attaching the ventilation member 70 to the front member 210.

[0124] Next, the front member 210 and the rear member 220 are connected. Specifically, the front end portion of the rear member 220 is inserted between the rear end portion of the front base portion 211 of the front member 210 and the first claw portion 212, and the second claw portion 213 of the front member 210 is engaged with the engagement hole 227 of the rear member 220, thereby connecting the front member 210 and the rear member 220. In this way, the lower cover member 200 is assembled.

[0125] Then, the lower cover member 200 is attached to the upper cover member 100. Specifically, as shown in Fig. 5, four tapping screws 93 are passed through the through holes 231 provided in the screw insertion portions 230 of the lower cover member 200 and fastened to the lower cover attachment portions 170 (see Fig. 7) of the upper cover member 100, thereby attaching the lower cover member 200 to the upper cover member 100. In this way, the case member 40 accommodating the blower 80 is assembled, as shown in Fig. 4.

[0126] The headrest S3 can be manufactured through the above steps. Thereafter, the headrest S3 is attached to an assembly including the seat cushion S1 and the seat back S2. Specifically, the headrest S3 is attached to the seat back S2 by inserting the pillar portion 31 of the headrest S3 into a headrest guide (not shown) held by a holder 26 (see FIG. 2) of the seat back S2. In this way, the vehicle seat S as shown in FIG. 1 can be manufactured.

[0127] The above-described method for manufacturing the vehicle seat S is an example, and the order of the steps may be changed as appropriate. For example, the blower 80 may be attached to the upper cover member 100 after the headrest pad P3 is formed. Also, the ventilation member 70 may be attached to the front member 210 after the front member 210 and the rear member 220 are connected to assemble the lower cover member 200.

[0128] According to the present embodiment described above, as shown in FIG. 8, the mounting member 50 can be positioned so as to fit within the area between the upper end E1 and the lower end E2 (see FIG. 4) of the headrest frame F3, and therefore the mounting member 50 can be positioned compactly.

[0129] Furthermore, since the mounting member 50 can be arranged so as to fit in an area behind the front end E3 of the headrest frame F3, the mounting member 50 provided on the headrest S3 can be arranged compactly.

[0130] Furthermore, the mounting member 50 can be arranged so as to fit in an area in front of the rear end E4 of the headrest frame F3, thereby enabling a compact arrangement of the mounting member 50. In particular, in a configuration in which the mounting member 50 is arranged behind the front end E3 of the headrest frame F3, as in the present embodiment, when the mounting member 50 is arranged in front of the rear end E4 of the headrest frame F3, the mounting member 50 can be arranged so as to fit in an area between the front end E3 and rear end E4 of the headrest frame F3, thereby enabling a more compact arrangement of the mounting member 50.

[0131] Furthermore, since the mounting member 50 can be arranged to fit within the area between the front end E5 and the rear end E6 of the blower 80 housed in the case member 40, the mounting member 50 can be arranged more compactly.

[0132] Furthermore, since the case member 40 attached to the mounting member 50 can be positioned to fit within the area between the upper end E1 and the lower end E2 of the headrest frame F3, the case member 40 provided on the headrest S3 can be positioned compactly.

[0133] 12, the mounting member 50 can be disposed between a pair of pillar parts 31, allowing for a more compact arrangement of the mounting member 50. The mounting member 50 can also be fixed so as to span the pair of pillar parts 31.

[0134] Furthermore, when the positioning portion 130 of the case member 40 is engaged with the engaging portion 53 of the mounting member 50, the rib 140 of the case member 40 can be abutted against the mounting member 50, thereby preventing the case member 40 from rattling relative to the mounting member 50.

[0135] Furthermore, since the engagement portion 53 is positioned between the tapping screws 91A and 91B, the case member 40 can be fixed to the mounting member 50 by the tapping screws 91A and 91B on both sides of the point where the position of the case member 40 relative to the mounting member 50 is determined.

[0136] Furthermore, since the mounting member 50 and the support member 60 are arranged with a gap therebetween, the mounting state of the case member 40 relative to the mounting member 50 can be confirmed even through the gap between the mounting member 50 and the support member 60.

[0137] Furthermore, according to this embodiment, since the case member 40 has an insertion hole 40H in its end region for passing the nozzle 320, when molding the headrest S3, the foaming resin material M can be injected into the mold 310 from a position offset to the front, rear, left or right relative to the center of the case member 40, so that the foaming resin material M can flow from the inner surface of the front, rear, left or right of the mold 310, through the bottom of the mold, and along the opposite inner surface of the front, rear, left or right.

[0138] 14(b), when molding the headrest pad P3, the foaming resin material M can be injected into the mold 310 from a position shifted rearward from the center of the upper cover member 100, and the foaming resin material M can flow from the rear inner surface 311 of the mold 310, through the bottom surface 312, and along the front inner surface 313. This makes it possible to prevent air bubbles from being generated in the headrest pad P3, thereby improving the moldability of the headrest pad P3.

[0139] Furthermore, because insertion hole 40H is positioned so as not to overlap blower 80 when viewed from the direction of penetration, nozzle 320 can be passed through insertion hole 40H even when blower 80 is housed in case member 40, more specifically, when attached to upper cover member 100. This improves the degree of freedom when manufacturing headrest S3. This improves, for example, the workability when manufacturing headrest S3.

[0140] Furthermore, because the insertion holes 40H are positioned so as not to overlap with the headrest frame F3, the mounting member 50, or the support member 60 when viewed from the penetration direction, when the nozzle 320 is passed through the insertion holes 40H to inject the foaming resin material M into the mold 310, the flow of the foaming resin material M is not blocked by the headrest frame F3, the mounting member 50, or the support member 60. This allows the foaming resin material M to flow smoothly, and the headrest pad P3 can be molded well.

[0141] Furthermore, by arranging the insertion hole 40H at a position between the pair of pillars 31 in the left-right direction, the insertion hole 40H can be arranged near the center of the headrest S3 in the left-right direction. This allows the foaming resin material M to flow more smoothly compared to, for example, a case where the insertion hole provided in the rear end of the case member is arranged offset to the left or right of the pillars, thereby improving the moldability of the headrest pad P3.

[0142] Furthermore, because the case member 40 can be separated into the upper cover member 100 and the lower cover member 200 and the insertion hole 40H is provided in the upper cover member 100, when molding the headrest S3, only the upper cover member 100 of the case member 40 can be set in the mold 310 and the foaming resin material M can be injected into the mold 310 through the insertion hole 40H with the nozzle 320. This improves the degree of freedom when manufacturing the headrest S3. This, for example, improves the workability when manufacturing the headrest S3.

[0143] 4, since the insertion hole 40H is provided at the rear end of the case member 40, when a load is applied to the headrest S3 from the front, the force is less likely to be applied to the vicinity of the insertion hole 40H of the case member 40. This makes it possible to prevent the vicinity of the insertion hole 40H of the case member 40 from being deformed.

[0144] Furthermore, since the insertion hole 40H is disposed behind the headrest frame F3, when a load is applied to the headrest S3 from the front, the load can be received by the headrest frame F3, thereby further suppressing deformation of the case member 40 near the insertion hole 40H.

[0145] Furthermore, as shown in FIG. 8, the housing portion 110 that houses the blower 80 does not have an insertion hole 40H, so that the rigidity of the housing portion 110 can be ensured.

[0146] 10, the rear member 220 that supports the front member 210 from behind has the pillar accommodating portion 222 that has a shape that surrounds the pillar portion 31 of the headrest frame F3 from the front and rear, so that the rear member 220 can be firmly supported by the pillar portion 31 of the headrest frame F3. As a result, for example, when a load is applied to the headrest S3 from the front, the front member 210 can be firmly supported by the rear member 220.

[0147] Furthermore, since the rear member 220 has the first rib 224, the rigidity of the rear member 220 can be improved, and the front member 210 can be supported by the rear member 220 more firmly.

[0148] Furthermore, since the rear member 220 has the second rib 225 and the third rib 226, the rigidity of the rear member 220 can be improved, and the front member 210 can be supported by the rear member 220 more firmly.

[0149] Furthermore, the rear member 220 has the rear base portion 221 that is positioned downwardly relative to the pillar accommodating portion 222, and the connecting portion 223 that connects the pillar accommodating portion 222 and the rear base portion 221, thereby improving the rigidity of the rear member 220. This allows the front member 210 to be more firmly supported by the rear member 220.

[0150] Furthermore, by positioning the left and right outer ends 223A of the connecting portion 223 located in front of the pillar portion 31 and the left and right outer ends 223B of the connecting portion 223 located behind the pillar portion 31 at the same position in the left-right direction, it is possible to further improve the rigidity of the rear member 220. This allows the front member 210 to be supported even more firmly by the rear member 220.

[0151] Furthermore, because the connection portion between the front member 210 and the rear member 220 is located forward of the pillar accommodating portion 222, a load applied from the front of the headrest S3 can be transmitted to the portion of the rear member 220 that is supported by the pillar portion 31 via the connection portion between the front member 210 and the rear member 220. This makes it possible to prevent the front member 210 and the rear member 220 from separating due to an impact.

[0152] 8, when the front member 210 is connected to the rear member 220, the rear member 220 can be clamped between the first claw portion 212 and the front base portion 211, thereby firmly connecting the front member 210 and the rear member 220. This makes it possible to further prevent the front member 210 and the rear member 220 from being separated due to an impact.

[0153] 11, the front member 210 is configured to clamp the rear member 220 between the first claw portion 212 and the front base portion 211, and further, as shown in Fig. 11, the second claw portion 213 of the front member 210 engages with the engagement hole 227 of the rear member 220, so the front member 210 and the rear member 220 can be more firmly connected. This makes it possible to further prevent the front member 210 and the rear member 220 from separating due to an impact.

[0154] Furthermore, since ventilation member 70 is provided as a separate member from case member 40, ventilation opening 71C can be molded separately from front member 210, which increases the degree of freedom in designing ventilation opening 71C and front member 210. This makes it possible, for example, to ensure that air sent out from blower 80 hits the seated occupant effectively and to improve the rigidity of front member 210.

[0155] Although the embodiment has been described above, the seat can be modified as appropriate as exemplified below.

[0156] In the above embodiment, the convex positioning portion 130 provided on the case member 40 is configured to engage with the engaging portion 53, which is a through hole provided on the mounting member 50. However, for example, a concave positioning portion provided on the case member may be configured to engage with a convex engaging portion provided on the mounting member. Also, the headrest may be configured such that the case member does not have a positioning portion and the mounting member does not have an engaging portion.

[0157] In the above embodiment, the case member 40 has four ribs 140, but the number of ribs is arbitrary and may be, for example, three or less, or five or more. Also, the case member may be configured without a rib that abuts against the mounting member when attached to the mounting member.

[0158] In the above embodiment, the tapping screws 91A to 91C are exemplified as the fixing members for fixing the case member 40 to the mounting member 50, but the fixing members may be, for example, bolts and nuts. Also, the headrest may be configured such that the engaging portions of the mounting members are not disposed between a plurality of fixing members.

[0159] In the above embodiment, the mounting member 50 and the support member 60 are not connected and are provided as separate members, but for example, the mounting member and the support member may be provided as an integrated member. That is, the mounting member may have a portion that supports the head of a seated occupant. Also, the headrest may not have a support member.

[0160] In the embodiment described above, the insertion hole 40H is provided in the edge (rear edge 122) provided behind the storage section 110 of the upper cover member 100, but for example, the insertion hole may be provided in the edge provided in front of the storage section. Also, the insertion hole may be provided in the edge provided on the left side of the storage section, or in the edge provided on the right side of the storage section.

[0161] In other words, in the above embodiment, the insertion hole 40H is provided at the rear end of the case member 40, but for example, the insertion hole may be provided at the front end of the case member. Also, the insertion hole may be provided at the left end or right end of the case member.

[0162] In other words, in the above embodiment, the case member 40 has the insertion hole 40H in the rear end region, but the case member may have the insertion hole in the front end region, or the case member may have the insertion hole in the left end region or the right end region.

[0163] In the above embodiment, the rear base portion 221 is configured to be positioned downwardly relative to the pillar accommodating portion 222, but for example, the rear base portion may be configured to be positioned upwardly relative to the pillar accommodating portion.

[0164] In the above embodiment, the first claw portion 212 and the second claw portion 213 protrude upward from the front base portion 211, but for example, the first claw portion and the second claw portion may protrude downward from the front base portion. Also, the front member may not have the second claw portion and the rear member may not have an engagement hole. Also, the front member may not have the first claw portion.

[0165] In the above embodiment, the left and right outer ends 223A of the connecting portion 223 located in front of the pillar portion 31 and the left and right outer ends 223B of the connecting portion 223 located in rear of the pillar portion 31 are located at the same position in the left-right direction, but for example, one end may be located more outward in the left-right direction than the other end. Also, the rear member may be configured not to include a connecting portion. Also, the rear member may be configured not to include at least one of the first rib, the second rib, and the third rib.

[0166] In the above embodiment, the ventilation member 70 is provided as a separate member from the front member 210. However, for example, the ventilation member may be provided as an integral member with the front member. In other words, the front member may have a ventilation opening.

[0167] In the above embodiment, the lower cover member 200 has a configuration including a front member 210 and a rear member 220. However, for example, the upper cover member may have a front member and a rear member, instead of the lower cover member. Also, both the upper cover member and the lower cover member may have a front member and a rear member.

[0168] Furthermore, the case member attached to the mounting member and the case member having an insertion hole may have a structure that is not divided into a front member and a rear member, and may further have a structure that is not divided into an upper cover member and a lower cover member.

[0169] In the above embodiment, the headrest frame F3 has a configuration including a pair of pillar portions 31 and a connecting portion 32 that connects the upper ends of the pillar portions 31 together. However, for example, the headrest frame may also be configured to include a pair of pillar portions that are not connected to each other.

[0170] In the above embodiment, a sirocco fan equipped with a heater is exemplified as blower 80, but for example, the blower may be a sirocco fan without a heater. Furthermore, the blower may be a blower other than a sirocco fan. Furthermore, in the above embodiment, blower 80 is exemplified as a device housed in case member 40, but it may also be a device other than a blower, such as a speaker.

[0171] In the above embodiment, the seat is exemplified as a vehicle seat S to be installed in an automobile, but the seat may be a vehicle seat to be installed in a vehicle other than an automobile, such as a railroad car, a ship, or an airplane. The seat may also be a seat other than a vehicle seat, such as a seat used in the home. For example, the seat may have a configuration in which the seat cushion and the seat back are integrally formed.

[0172] The elements described in the above-described embodiment and modified examples may be implemented in any combination. [Explanation of symbols]

[0173] 31 Pillar section 40 Case material 40H insertion hole 60 Support member 80 Blower 100 upper cover member, 110 Storage unit 120 Edge 121 leading edge 122 Trailing edge 123 Left edge 124 Right edge 200 Lower cover member 310 type 320 nozzle F1 seat cushion frame F2 seat back frame F3 headrest frame M foam resin material P1 seat cushion pad P2 seat back pad P3 headrest pad S vehicle seat S1 seat cushion S2 seat back S3 Headrest SK1 seat cushion cover SK2 seat back skin

Claims

1. A seat equipped with a headrest, the headrest includes a case member that houses an apparatus, and a headrest pad made of foamed resin that is in close contact with the case member; The case member is a first cover member having an insertion hole for passing a nozzle for injecting the foaming resin material in a front, rear, left or right end region; a second cover member attached to the first cover member, The sheet is characterized in that, when attached to the first cover member, the second cover member covers the device and the insertion hole from the direction in which the insertion hole passes.

2. the headrest includes a headrest frame to which the case member is attached, The seat according to claim 1, wherein the insertion hole is disposed behind a rear end of the headrest frame.

3. The first cover member has an equipment mounting portion for mounting the equipment, 3. The seat according to claim 1, wherein the device mounting portion is provided between a main body of the device and the insertion hole.

4. The headrest frame has a pair of pillar portions spaced apart from each other on the left and right, the first cover member has a pair of pillar insertion holes through which the pillar portions pass, 3. The seat according to claim 2, wherein the insertion hole is disposed between the pair of pillar insertion holes in the left-right direction and behind the pair of pillar insertion holes.

5. The second cover member has a pair of pillar accommodating portions through which the pillar portions pass, The seat according to claim 4, wherein the pillar accommodating portion has a cutout for passing the pillar portion therethrough, the cutout having openings on both left and right outer sides.

6. The second cover member has a through hole for passing a harness connected to the device, 6. The sheet according to claim 1, wherein the insertion holes are arranged at positions that do not overlap with the through holes in a direction in which the insertion holes penetrate.

7. the first cover member has a storage portion that is recessed from bottom to top and an edge portion provided on the front, rear, left, or right of the storage portion; 7. The sheet according to claim 1, wherein the insertion hole is provided in the edge portion.

8. the first cover member has a plurality of the end regions; 8. The sheet according to claim 1, wherein the end region in which the insertion hole is provided is located higher than the other end regions.

9. A seat cushion and a seat back are provided, the seat cushion includes a seat cushion frame, a seat cushion pad that covers the seat cushion frame, and a seat cushion skin that covers the seat cushion frame and the seat cushion pad, 9. The seat according to claim 1, wherein the seat back comprises a seat back frame, a seat back pad that covers the seat back frame, and a seat back skin that covers the seat back frame and the seat back pad.

10. A method for manufacturing a seat comprising: a case member for accommodating equipment; and a headrest pad made of foamed resin in close contact with the case member, the case member having, at a front, rear, left or right end region thereof, a first cover member having an insertion hole for passing a nozzle for injecting material for the foamed resin therethrough; and a second cover member attached to the first cover member, the second cover member attached to the first cover member, the seat comprising: a case member for accommodating equipment; and a headrest pad made of foamed resin in close contact with the case member, the case member having, at a front, rear, left or right end region thereof, a first cover member having an insertion hole for passing a nozzle for injecting material for the foamed resin therethrough; setting the first cover member in a mold; passing the nozzle through the insertion hole; injecting the foaming resin material into the mold from the nozzle; and attaching the second cover member to the first cover member.

11. The first cover member has a plurality of the end regions, The sheet manufacturing method described in claim 10, characterized in that in the process of setting the first cover member in a mold, the first cover member is set in the mold so that the end region in which the insertion hole is provided among the multiple end regions is positioned lower than the other end regions.

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